Harness Assembly Rigidity Zoning to Avoid Rotary Contact
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Solution Overview
Problem
Existing harness assemblies face difficulties in controlling the trajectory to avoid contact with rotary members during connection to connectors, especially when the assembly is long and flexible, requiring careful work to prevent interference.
Innovation Solution
The harness assembly is sectioned into high-rigidity and low-rigidity portions, with the wire harness covered by a protection tube in the high-rigidity portion and partially uncovered in the low-rigidity portion, allowing the assembly to be bent at the low-rigidity portion to avoid contact with rotary members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the harness assembly is made long enough to connect the wire harness to the connector of the housing, then the workability of connecting is improved, but the rigidity decreases making it difficult to control the trajectory
Solution Approach 1:
The protection tube is divided into a first protection tube and a second protection tube that are detachably connected. The first protection tube has a first holding portion that holds a first connector, and the second protection tube has a second holding portion that holds a second connector. This segmentation allows the harness assembly to be connected in sections, improving workability while maintaining trajectory control through the structured connection points.
Solution Approach 2:
The protection tube acts as an intermediary structure that holds the connectors and guides the harness assembly trajectory. The detachable connection between the first and second protection tubes provides intermediate connection points that facilitate controlled assembly while maintaining overall trajectory control.
2Ease of operation
If the harness assembly is made flexible to improve trajectory control, then the ease of operation is improved, but the reliability of avoiding contact with rotary members deteriorates
Solution Approach 1:
The first holding portion and second holding portion are provided in advance on the first and second protection tubes respectively. These holding portions pre-position the connectors at specific locations, ensuring that when the harness assembly is connected, the trajectory automatically avoids contact with the rotary member without requiring additional flexible adjustments during assembly.
Solution Approach 2:
The protection tube structure with its holding portions automatically guides the harness assembly trajectory during connection. The design self-regulates the path of the wire harness through the spatial arrangement of the holding portions, eliminating the need for manual trajectory control while maintaining reliability.
3Reliability
If the protection tube covers the entire wire harness, then the protection is improved, but the flexibility and ease of bending deteriorates
Solution Approach 1:
The protection tube is segmented into a first protection tube and a second protection tube with a detachable connection between them. This segmentation allows the wire harness to be protected where needed while providing flexible connection points that enable easy bending and trajectory adjustment during assembly operations.
Data Source
AI summary
A harness assembly for connecting between an actuator disposed in a housing that houses a rotary member, and a connector that is fixed to the housing. The harness assembly includes a wire harness and a protection tube covering the wire harness. The wire harness is to be connected at its end portion to the actuator, and at its another end portion to the connector. The harness assembly is sectioned into a high-rigidity portion and a low-rigidity portion. The wire harness is covered with the protection tube in the high-rigidity portion, and such that the wire harness is at least partially uncovered with the protection tube in the low-rigidity portion. The low-rigidity portion is provided in a position that avoids the harness assembly from being brought into contact with the rotary member, by being bent at the low-rigidity portion when the other end portion is connected to the connector.