Cable Assembly Strapping Loops for Compact Automated Bundling
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Solution Overview
Problem
The existing methods for bundling and strapping cable sets are difficult to automate due to the need for extensive space and the use of wrapping tape, which complicates the attachment of holding parts and integration with vehicle assemblies.
Innovation Solution
A method and device that use a strapping material, such as thermoplastic textiles, to form a loop around the cable set, which is then welded or glued to securely bundle and attach the cable set, reducing space requirements and enabling automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wrapping tape is used to bundle wiring harnesses in a rotational motion, then the harness can be bundled and strapped, but considerable space is required and the process is difficult to automate
Solution Approach 1:
The patent replaces the mechanical rotational wrapping system with a linear insertion system. Instead of rotating a tape roll around the harness, a pre-formed loop of strapping material is inserted through the harness and then secured by welding the ends together. This substitution eliminates the complex rotational motion mechanism and reduces the space required for the bundling operation.
Solution Approach 2:
The patent changes the fundamental parameter of how strapping material is applied - from continuous rotational wrapping to discrete loop insertion followed by welding. This parameter change transforms the process from space-intensive rotational motion to a compact linear insertion process that is easier to automate.
2Extent of automation
If retaining clips are attached by wrapping them around the tape, then the wiring harness can be secured, but the process poses challenges for automation technology
Solution Approach 1:
The patent merges the strapping material and retaining clips into a single integrated component. The retaining clips are pre-attached to the strapping material during manufacturing, creating a unified assembly. This eliminates the separate operations of attaching clips to the harness after strapping, significantly simplifying the process and enabling full automation.
Solution Approach 2:
The retaining clips are pre-attached to the strapping material in advance during the strapping material manufacturing process. This preliminary action eliminates the need for complex automated operations to attach clips to the harness after the strapping process, reducing device complexity and improving automation capability.
3Extent of automation
If welding is used to join strapping material ends, then secure connection is achieved with easy automation, but the strapping material must be thermoplastic
Solution Approach 1:
The patent changes the material parameter from general-purpose wrapping tape to thermoplastic strapping material that can be welded. This parameter change enables secure permanent connections through welding, which is easily automated, while the thermoplastic materials remain widely available and suitable for the application.
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
This approach allows for fully automated bundling and attachment of cable sets with reduced space usage, increased production efficiency, and the use of sustainable materials, eliminating the need for adhesives and minimizing environmental impact.
Implementation Method 1
a welding unit (105) for welding the end of the strapping material (120) guided around the cable set (110) to the portion of the strapping material (120) not guided around the cable set (110)
Data Source
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AI summary
A method for forming a strapping section of a cable assembly (110) is proposed. The method comprises the steps of providing a strapping material (120) and guiding one end of the strapping material (120) around at least a part of the cable assembly (110). Furthermore, the method includes the step of joining the end of the strapping material (120) that is guided around the cable set (110) with a portion of the strapping material (120) that is not guided around the cable set (110), wherein the strapping material (120) forms a loop (130) through which the cable set (110) passes, as well as the steps of adjusting the size of the loop (130) to the cable set (110) to bundle the cable set (110), and welding the end of the strapping material (120) that is guided around the cable set (110) with the portion of the strapping material (120) that is not guided around the cable set (110).