Cable Harness Routing Element With Dual Suction-Cup Stability
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Solution Overview
Problem
Cable harness manufacturing systems face challenges in accommodating the increasing size and complexity of components and cables, requiring adjustable and extendable tooling components that ensure user access to all portions of the cable harness while maintaining stability and security.
Innovation Solution
The introduction of a routing element with an upper fixture support and a lower suction holder featuring multiple suction cups, which provide secure attachment and stability to the assembly board, along with adjustable features and guide elements for orientation and alignment, allowing for flexible placement and improved visibility during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single suction holder is used to attach the routing element to the assembly board, then the attachment mechanism is simple, but the stability and security of the cable harness during manufacture is insufficient
Solution Approach 1:
The routing element is divided into distinct functional portions: a lower suction holder portion with multiple suction cups for attachment to the assembly board, and an upper fixture support portion for supporting tooling components and cable harness. This segmentation allows each portion to be optimized independently - the lower portion provides stable attachment while the upper portion provides support functionality.
2Strength
If the footprint of the upper fixture support is made large to support complex cable harnesses, then the support capacity is improved, but the stability at the assembly board decreases
Solution Approach 1:
The routing element utilizes vertical dimensionality by extending the lower suction holder outwardly beyond the upper fixture support in the vertical direction. This creates a stepped configuration where the larger footprint is positioned at the lower attachment portion rather than the upper support portion, maintaining stability at the board while providing adequate support capacity.
3Force
If the lower suction holder extends outwardly beyond the upper fixture support, then the surface contact area and suction force are increased, but the device complexity increases
Solution Approach 1:
The routing element merges the lower suction holder portion and upper fixture support portion into a single integrated component. This combination eliminates the need for separate attachment mechanisms and support structures, reducing overall device complexity while achieving increased suction force through the extended lower portion with multiple suction cups.
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
The solution enhances stability and security of tooling components and cable harnesses, enabling the manufacturing of complex cable types by providing increased surface contact area, suction force, and flexibility in cable fixing element placement, while allowing for user access from various angles.
Implementation Method 1
a lower suction holder including at least two suction cups for attaching the routing element to the assembly board
Implementation Method 2
The use of multiple suction cups provides an increased suction force
Data Source
AI summary
A routing element for a cable harness manufacturing system includes an assembly board having an attachment surface configured for receiving tooling components to support and locate a cable harness during manufacture. The routing element includes: an upper fixture support having an aperture for receiving a tooling component to support the cable harness during manufacture; and a lower suction holder including two suction cups for attaching the routing element to the assembly board. The lower suction holder and the upper fixture support are located axially about a central vertical axis of the routing element. The lower suction holder extends outwardly relative to the upper fixture support, such that the area covered by the lower suction holder is greater than that of the upper fixture support. Also provided is a cable harness manufacturing system and a kit including routing elements, spacer elements and support plates for a cable harness assembly board.