Composite Wire Harness Layout for Connector-Friendly Assembly

Solution Overview

Problem

The existing composite wire harnesses face challenges in assembly workability due to the need for connectors to be passed through metal pipes, which limits the diameter of the pipes and complicates the assembly process, especially when trying to reduce weight and size.

Innovation Solution

A composite wire harness design that includes a first wire harness with a first exterior tube and a second wire harness with a second exterior tube, along with a path regulating member that partially covers the exterior tubes, providing an insertion port for attaching connectors after terminal processing, thereby improving assembly workability and reducing the number of components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If the diameter of the metal pipe is reduced to minimize weight and size, then weight and size are reduced, but connectors cannot be passed through the pipe during assembly

Engineering Contradiction:

Improveweight of wire harnessVSAvoidassembly workability

Core Design Contradiction:

Weight of moving objectVSEase of operation

Solution Approach 1:

The protective covering is divided into two distinct parts: exterior tubes that protect individual wire harnesses (first and second wire harnesses) and a separate path regulator that guides and positions them. This segmentation allows each component to be optimized independently - exterior tubes can be thin-walled for weight reduction while the path regulator provides the necessary structural guidance, eliminating the need for a single thick-walled metal pipe that would prevent connector passage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The path regulation function is extracted from the protective covering structure. Instead of using a metal pipe that combines both protection and path regulation (which limits diameter and increases weight), the patent uses separate exterior tubes for protection and a dedicated path regulator component for guidance. This extraction allows the protective tubes to be minimized in diameter and wall thickness while maintaining assembly workability through the separate path regulator.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of operation

If a single metal pipe is used to protect the wire harness, then protection is provided, but the pipe diameter must be large enough to allow connector passage, increasing weight and size

Engineering Contradiction:

Improveassembly workabilityVSAvoidweight of wire harness

Core Design Contradiction:

Ease of operationVSWeight of moving object

Solution Approach 1:

The protective covering is divided into two distinct parts: exterior tubes that protect individual wire harnesses (first and second wire harnesses) and a separate path regulator that guides and positions them. This segmentation allows each component to be optimized independently - exterior tubes can be thin-walled for weight reduction while the path regulator provides the necessary structural guidance, eliminating the need for a single thick-walled metal pipe that would prevent connector passage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The path regulator is designed to be attached to the exterior tubes after the wire harnesses are assembled, but before final installation. This preliminary attachment provides path regulation guidance early in the assembly process, allowing connectors to be attached to end portions without needing to pass through a large-diameter pipe, thereby reducing overall weight and size while maintaining assembly workability.

Inventive Principle:

Principle #10Preliminary action

3Weight of moving object

If the metal pipe diameter is minimized for weight reduction, then weight is reduced, but the path regulation capability is compromised

Engineering Contradiction:

Improveweight of wire harnessVSAvoidpath regulation capability

Core Design Contradiction:

Weight of moving objectVSDevice complexity

Solution Approach 1:

The protective covering is divided into two distinct parts: exterior tubes that protect individual wire harnesses (first and second wire harnesses) and a separate path regulator that guides and positions them. This segmentation allows each component to be optimized independently - exterior tubes can be thin-walled for weight reduction while the path regulator provides the necessary structural guidance, eliminating the need for a single thick-walled metal pipe that would prevent connector passage.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The path regulator merges multiple functions into a single component: it regulates the path of both the first and second wire harnesses simultaneously, provides structural support, and maintains proper spacing between harnesses. This merging eliminates the need for separate regulation mechanisms for each wire harness, reducing overall complexity despite the minimized diameter of individual exterior tubes.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS20230382321A1Composite wire harness

Publication Date: 2023.11.30 SUMITOMO WIRING SYSTEMS LTD

AI summary

A composite wire harness, including: a first wire harness including a first electric wire and a first exterior tube covering the first electric wire; a second wire harness including a second electric wire and a second exterior tube covering the second electric wire; and a first path regulator configured to be attached to the first wire harness and the second wire harness.