Flat Exterior Wiring Harness Routing in Tight Electrical Clearances
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Solution Overview
Problem
Existing wiring harnesses complicate the routing of wires between electrical components due to their design, leading to inefficient use of space and potential durability issues.
Innovation Solution
An exterior wiring harness featuring a flat portion with a smaller minor axis length than the clearance between electrical members, allowing it to be routed in tight spaces, combined with circular portions for added design flexibility and durability through the use of a fibrous synthetic resin sheet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional wiring harness with bundled wires is used, then the wires are protected and organized, but the routing space required increases and space efficiency decreases
Solution Approach 1:
The exterior body is formed with a flat cross-sectional shape instead of a conventional circular shape, allowing the wiring harness to be routed in the thickness direction (minor axis direction) of electrical members. This dimensional change enables the wiring harness to utilize previously unused flat spaces between electrical members, thereby reducing the required routing space and improving space efficiency.
2Productivity
If the exterior body is made completely flat to fit in clearances, then space efficiency improves, but the mechanical strength and flexibility decrease
Solution Approach 1:
The exterior body is designed with different cross-sectional shapes at different locations: a flat cross-sectional shape at the flat portion for fitting in clearances, and a circular cross-sectional shape at the circular portion for maintaining mechanical strength and flexibility. This local differentiation allows the wiring harness to achieve both space efficiency in routing areas and structural integrity in other areas.
Data Source
AI summary
It is aimed to provide an exterior wiring harness which can be routed in a flat space formed between a plurality of electrical members. An exterior wiring harness (10) includes a plurality of wires (11) and an exterior body (12) formed by surrounding outer peripheries of the plurality of wires (11) by a sheet (13) made of fibrous synthetic resin. The exterior body (12) includes a flat portion (15) having a flat cross-sectional shape and other parts (14) connected to the flat portion (15) and different from the flat portion. A length (L1) of the flat portion (15) in a minor axis direction is set to be smaller than a width of a clearance formed between a plurality of electrical members. A maximum value (L3) of the other parts (14) in the minor axis direction of the flat portion is set to be larger than the width of the clearance.