Flat Surface Wire Harness Ultrasonic Joining
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Solution Overview
Problem
The existing wire harness manufacturing process is complicated due to the need for precise shaping of conductor exposed portions during core wire joining, which can lead to distortion and processing inaccuracies.
Innovation Solution
A wire harness design where core wires have pre-formed flat surfaces extending along their lengths, allowing for easy overlap and joining without the need for precise shaping, using ultrasonic welding to ensure reliable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conductor exposed portion is collapsed to ensure proper joining, then the join portion reliability is improved, but the forming process becomes complicated and manufacturing precision deteriorates
Solution Approach 1:
The core wires are pre-formed with flat surfaces extending along their entire lengths before the joining process. This preliminary shaping eliminates the need for complex collapsed portion formation during assembly, simplifying the manufacturing process while ensuring reliable ultrasonic welding between the flat surfaces of the core wires
2Manufacturing precision
If the conductor exposed portion is formed with high accuracy, then the join portion distortion is prevented, but the manufacturing time increases
Solution Approach 1:
The flat surfaces on the core wires are formed in advance during wire manufacturing, not during assembly. This preliminary action ensures high manufacturing precision of the joining surfaces without adding time to the wire harness assembly process, as the flat surfaces are already prepared on the core wires before they are routed and connected
3Manufacturing precision
If the core wires are joined with precise shaping, then the join quality is improved, but the ease of manufacture deteriorates
Solution Approach 1:
The invention changes the geometric parameter of the core wire from a conventional circular cross-section to a flat surface configuration extending along the wire length. This parameter change enables simple overlapping and ultrasonic welding of the flat surfaces, dramatically improving ease of manufacture while maintaining high join quality through the large contact area of the flat surfaces
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 design simplifies the manufacturing process, increases processing accuracy, and enhances the flexibility and reliability of the wire harness by allowing for discretionary joining positions and reduced kinking, while maintaining high rigidity and ease of bending.
Implementation Method 1
the individual wire exposed portion is joined to a planar portion of the collapsed portion via ultrasonic welding
Data Source
AI summary
A wire harness, including: a first wire including a first core wire and a second wire including a second core wire, the first core wire and the second core wire being joined together, wherein the first core wire includes a first flat surface extending along an entire length of the first core wire in a length direction, the second core wire includes a second flat surface extending along an entire length of the second core wire in a length direction, and the first flat surface and the second flat surface are overlapped and joined.