Motorcycle Handle Bar Joint Flaring for Wire Harness Routing

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Solution Overview

Problem

Traditional motorcycle handle bars with intersecting pipe designs pose challenges for internally routed wire harness assemblies due to restricted internal pivot radii, requiring disassembly and excessive force to pass the wire coupling, which can lead to damage and increased costs.

Innovation Solution

The design involves flaring or adjusting the periphery of the pipe ends at the joint to increase the pivot radius, allowing for smoother passage of the wire harness assembly without disassembly, using methods like heating, cutting, and notching to form a larger periphery and notch configurations that accommodate the wire harness without damaging it.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the handle bar uses intersecting pipe design with angled corners, then the structural strength and rigidity are improved, but the internal pivot radius is reduced making wire harness passage difficult

Engineering Contradiction:

Improvestructural strengthVSAvoidwire harness passage

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The joint is divided into multiple components including a first pipe, a second pipe, and a separate coupling member. This segmentation allows the coupling member to provide a larger internal pivot radius for wire harness passage while the pipes maintain their structural strength through their own rigid construction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A coupling member acts as an intermediary component between the first pipe and second pipe. This coupling member specifically addresses the wire harness passage problem by providing a larger internal pivot radius, while still allowing the intersecting pipe design to maintain its structural integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the internal pivot radius is reduced for compact design, then the handle bar size is minimized, but excessive force is required to pull wires through causing damage risk

Engineering Contradiction:

Improvehandle bar sizeVSAvoidwire damage risk

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The coupling member has different local qualities: a larger internal pivot radius where wires pass through to prevent damage, and a compact overall structure to minimize handle bar size. This local differentiation allows simultaneous achievement of compact size and wire protection.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The coupling member is designed in advance with an optimized internal pivot radius that accommodates wire harness passage before installation. This preliminary design prevents the need for excessive pulling force during installation, thereby preventing wire damage.

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If traditional rigid coupling is used in intersecting pipe design, then manufacturing simplicity is maintained, but disassembly and reassembly are required for wire installation increasing cost

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidassembly process

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The coupling member serves multiple functions: it connects the first pipe and second pipe structurally, provides a large internal pivot radius for wire harness passage, and allows for easy assembly and disassembly. This multi-functionality resolves the contradiction between manufacturing simplicity and assembly complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The coupling member is designed to be dynamically removable and reattachable, allowing wire harness installation without permanent disassembly. This dynamic design simplifies the overall process by enabling easy access for wire routing while maintaining structural integrity.

Inventive Principle:

Principle #15Dynamics

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 solution enables the wire harness assembly to pass through the handle bar joint without requiring excessive force or disassembly, reducing the risk of damage and lowering modification costs by increasing the internal pipe arc and pivot radius, thus facilitating easier installation and maintenance.

Implementation Method 1

at least one of the first open end and the second open end is flared

Methodology Applied

Scientific EffectFlaring:

Implementation Method 2

heating an angled end of a first pipe... flaring the first open end of the first pipe

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS10882578B2Increasing the internal pivot radii for angle-joined motorcycle handle bars

Publication Date: 2021.01.05 MAGNUM SHIELDING CORP

AI summary

A motorcycle metal handle bar assembly for receiving a length of an internally routed wire harness assembly. The motorcycle metal handle bar assembly includes a first pipe having a first open end defined by a first angled cut, wherein the first open end defines a first periphery; a second pipe having a second open end defined by a second angled cut, wherein the second open end defines a second periphery; a joint at an interface of the first open end and the second open end, wherein at least one of the first open end and the second open end is flared.