Automated Cable Harness Bundling via Sprayable Fiber Suspension
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing cable harnesses, such as taping and using corrugated tubes, require manual labor and lack automation, increasing production costs.
Innovation Solution
A method involving a textile-type fiber interlacement created by applying a suspension of binding agent and loose fibers to the line bundle, which solidifies into a woven fabric-like bundling element, adaptable to various geometries and surfaces, allowing for automated production and flexible application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If taping or corrugated tubes are used to bundle lines, then the lines are held together as a bundle, but the process requires manual labor and cannot be readily automated
Solution Approach 1:
The patent replaces manual mechanical operations (wrapping tape, inserting lines into corrugated tubes) with an automated spray application system. The suspension is applied via spray nozzle to automatically form the bundling element, eliminating the need for manual labor while maintaining effective line bundling.
Solution Approach 2:
The patent changes the physical state and application method of the bundling material from pre-formed solid structures (tape, tubes) to a sprayable suspension that transforms into a fiber interlacement. This parameter change enables automated application while achieving the same bundling function.
2Adaptability or versatility
If classic injection molding is used to configure cable sheaths, then discrete locations are molded, but the process requires molds and is not easily adaptable to complex geometries
Solution Approach 1:
The patent uses a flexible sprayable suspension that can conform to any geometry, replacing rigid molds. The liquid suspension adapts to complex shapes and surfaces, eliminating the need for custom molds for each geometric configuration.
Solution Approach 2:
The spray application system serves multiple functions: it can bundle lines, form protective sheaths, and adapt to various geometries all through the same process, eliminating the need for different molds for different applications.
3Productivity
If manual wrapping or insertion methods are used, then bundling elements are applied, but production costs increase due to lack of automation
Solution Approach 1:
The patent replaces manual mechanical operations with an automated spray system that applies the suspension uniformly and efficiently, significantly increasing production speed and reducing labor costs while maintaining simple manufacturing principles.
Solution Approach 2:
The spray application process allows continuous production without the stop-start nature of manual operations. The suspension can be continuously applied along the line bundle, improving production efficiency and throughput.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables automated production of cable harnesses with a bundling element that adapts to complex shapes, reducing production costs and improving efficiency by eliminating the need for manual wrapping and complex molds.
Implementation Method 1
a suspension which includes a binding agent and loose fibers is applied to the line bundle... which solidifies into a woven fabric-like bundling element
Data Source
AI summary
A method for producing a cable harness, in particular for the motor vehicle industry, includes combining a plurality of individual lines into a line bundle. The line bundle is provided with a bundling element. The bundling element is constructed as a textile-like fiber interlacement or weave which is produced by applying a suspension including fibers and a binder to the line bundle. A cable harness produced by the method is also provided.