Cable Insertion Aid Thickened Head Design
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Solution Overview
Problem
Existing cable insertion aids in the automotive industry face challenges with attachment durability and adaptability, as the ball attachment to a flat, elastically bendable insertion element often tears off during use, and the need for various lengths and sizes complicates easy and safe cable harness laying.
Innovation Solution
A thickened head with snap indentations on the insertion element, which can be adapted with a rounded cap of varying shapes, ensures secure attachment and adjustable length, allowing for easy and safe cable insertion without the risk of the attachment falling off or breaking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a ball with internal thread is attached to an external thread on a flat, elastically bendable insertion element, then the insertion aid can be adapted to different laying situations, but the attachment tears off during use or the ball breaks off and remains in the insertion channel
Solution Approach 1:
The insertion element is divided into functionally distinct segments: a flat, elastically bendable body for navigation and a thickened head for secure attachment. This segmentation allows each part to optimize its specific function while working together as a unified system.
Solution Approach 2:
The thickened head is designed with a rounded, bulbous shape that provides a larger surface area and more favorable geometry for attachment connections compared to the flat insertion element body. This curved geometry distributes stresses more effectively and prevents attachment failure.
2Adaptability or versatility
If multiple insertion elements of different lengths are used to meet individual requirements, then adaptability to different channels is improved, but device complexity and the number of components increase
Solution Approach 1:
The insertion element incorporates an elastically bendable flat body that can dynamically adapt its shape and configuration during insertion. This dynamic flexibility allows a single design to navigate various channel geometries without requiring multiple rigid variants.
Solution Approach 2:
The standardized thickened head with uniform attachment features creates a universal interface that can be used across insertion elements of different lengths and configurations, reducing the need for multiple specialized components.
3Ease of operation
If the insertion element is made elastically bendable for easy insertion, then ease of operation is improved, but the attachment connection becomes weaker and more prone to failure
Solution Approach 1:
The insertion element is divided into functionally distinct segments: a flat, elastically bendable body for navigation and a thickened head for secure attachment. This segmentation allows each part to optimize its specific function while working together as a unified system.
Solution Approach 2:
Different parts of the insertion element have different mechanical properties: the body is elastically bendable for easy insertion, while the head is thickened and rigid to provide strong attachment connections. This local differentiation of material properties optimizes both ease of operation and connection strength.
Data Source
Figure 1
Figure 1~2
Figure 3~5
AI summary
The aid has a hose (1) made of textile material and connected with elongated elastic bendable feed element (4). An end of the feed element turned away from the hose includes a thickened head (5) connected with the feed element as a single piece. The head includes a rounded-off tip (9) whose diameter is larger than width of the feed element. The tip is connected with the feed element by a transition region. The transition region extends over length that corresponds to diameter of the tip. The head includes locking recesses for accommodating locking pins of a cap.