Carrier Mesh Cable Set Assembly for Stable Harness Handling
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Solution Overview
Problem
The production and handling of prefabricated cable sets in the automotive industry are complex and time-consuming due to their flexible and dimensionally unstable nature, requiring significant manual effort and complex bundling methods, which complicates assembly and transportation.
Innovation Solution
A method involving a carrier network with a flat, flexible structure where cables are laid directly on the network without a cover layer, simplifying attachment and handling by eliminating the need for additional fastening layers and allowing for automated or manual laying, with the network serving as a support and separating element during transport.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cables are individually attached to a foil-like carrier with mesh structure and adhesive layers, then attachment to support components is simplified, but the structure becomes more complex and requires additional materials
Solution Approach 1:
The patent removes the adhesive layer and one insulation layer from the carrier structure, allowing cables to be held in position by the mesh structure alone. This extraction of unnecessary components simplifies the overall structure while maintaining the attachment function.
Solution Approach 2:
The mesh structure of the carrier automatically holds and positions the cables through its geometric configuration, eliminating the need for external adhesive layers. The structure serves its own function of securing cables without requiring additional fastening materials.
2Manufacturing precision
If cables are laid manually or semi-automatically with complex bundling methods, then precise laying geometry is achieved, but production time and labor increase significantly
Solution Approach 1:
The carrier mesh is pre-configured with the final laying geometry of the cables before production begins. Cables are laid directly onto this pre-formed mesh structure, which automatically maintains the correct geometric arrangement, eliminating the need for complex bundling operations during assembly.
Solution Approach 2:
The patent combines the carrier function and the geometric positioning function into a single mesh structure. The carrier mesh simultaneously provides support, maintains laying geometry, and enables automated cable placement, merging multiple functions that would otherwise require separate components and operations.
3Adaptability or versatility
If prefabricated cable harnesses are made flexible for adaptability, then installation flexibility is improved, but dimensional stability deteriorates making handling difficult
Solution Approach 1:
The patent uses a flexible mesh structure as the carrier that can be easily handled and adapted to different installation geometries. The mesh's inherent flexibility allows it to conform to various shapes while maintaining its structural integrity and the positioned cables during transport and installation.
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
To produce a pre-assembled cable set (2) with multiple conductors (12), a carrier mesh (4) is placed on a laying board (6). The carrier mesh has a plurality of openings (16) separated from each other by dividers (14). The conductors (12) are laid on one side of the carrier mesh (4) and attached to it without a cover layer. The conductors (12) are positively secured to the carrier mesh (4) using fastening elements (26), such as cable ties.