External Part Mounted Electric Wire for Wiring Harness
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Solution Overview
Problem
The existing wiring harness fabrication method is complex and time-consuming due to the manual adjustment of external parts, leading to reduced mounting accuracy, which varies with the skill level of the worker and the conditions of the electric wires.
Innovation Solution
The method involves using a mold to precisely position external parts, such as clips, on the electric wire during injection molding, ensuring they are aligned with predetermined positions on the panel, thereby eliminating the need for manual adjustment and enhancing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of external parts is used in the external part mounting step, then the mounting positions can be adjusted, but the fabrication process becomes complex and time-consuming
Solution Approach 1:
The mold is designed with predetermined mounting positions for external parts before the wiring harness fabrication process begins. During injection molding, the external parts are automatically positioned at these predetermined locations, eliminating the need for subsequent manual adjustment operations. This preliminary positioning action resolves the contradiction by achieving both accurate mounting and process simplification.
Solution Approach 2:
The injection molding process itself performs the positioning function that would otherwise require separate manual adjustment operations. The mold structure integrates the positioning capability directly into the manufacturing process, making the system self-sufficient and eliminating the need for additional adjusting jigs and manual intervention.
2Manufacturing precision
If manual adjustment of external parts is used, then mounting positions can be modified, but the required time for fabrication increases
Solution Approach 1:
The mold incorporates predetermined mounting positions for external parts before production begins. During injection molding, parts are automatically placed at these pre-determined locations, eliminating time-consuming manual adjustment operations and significantly reducing total fabrication time while maintaining consistent mounting accuracy.
Solution Approach 2:
The injection molding process combines multiple operations into a single step: manufacturing the electric wire, positioning external parts, and mounting them simultaneously. This merging of operations eliminates the separate external part mounting step and its associated manual adjustment time, directly improving productivity.
3Manufacturing precision
If adjusting jig is used for mounting external parts, then positioning can be achieved, but the process becomes complicated
Solution Approach 1:
The injection molding process inherently provides the positioning function that would otherwise require separate adjusting jigs. The mold structure itself performs the positioning and mounting operations, making the process self-service and eliminating the need for additional positioning tools and complex adjustment procedures.
Solution Approach 2:
The mold integrates the positioning and mounting functions into the injection molding process itself, combining what would otherwise be separate operations (positioning with adjusting jigs and mounting separately) into a single integrated process, thereby simplifying manufacturing.
4Productivity
If multiple working persons perform adjusting work, then mounting can be completed, but mounting accuracy varies depending on skill level
Solution Approach 1:
The injection molding process automatically performs the positioning and mounting operations without requiring skilled manual adjustment workers. The system serves itself by using the mold's predetermined positions and automated injection process, eliminating variability introduced by different workers' skill levels and ensuring consistent mounting accuracy.
Solution Approach 2:
The manual mechanical adjustment process performed by workers is replaced with an automated injection molding process controlled by machinery. This substitution eliminates human skill variability and ensures consistent, repeatable mounting accuracy across all production batches.
Data Source
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AI summary
To provide an external part mounted electric wire for a wiring harness laid on a panel making up a motor vehicle which increases the mounting accuracy of an external part mounted on the wiring harness and which simplifies the fabrication of the wiring harness. An external part mounted electric wire 1 includes an external part 3 which is mounted on an electric wire 2 so as to be brought into engagement with a hole in a panel on which a wiring harness 25 is laid. The external part 3 is made of a resin and is formed integrally with the electric wire 2. In addition, a relative position of the external part 3 to the electric wire 2 is provided in such a position that the external part 3 can be brought into engagement with the hole in the panel.