Motorcycle Headlight Harness Routing and Assembly
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Solution Overview
Problem
The handling of wire harnesses during the assembly of lighting devices is cumbersome due to the need to push them into a rear cover, which complicates the assembling process.
Innovation Solution
A lighting device design featuring a stay between the light source unit and the front frame, with a fixing portion for the electrical harness on the stay, allowing the harness to be routed around the light source unit in a counterclockwise direction and fixed at the upper portion, and the front frame is secured to the bottom bridge with a screw member, facilitating easier assembly and reducing twisting loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wire harness is pushed into the rear cover during assembly, then the lighting device can be assembled, but the handling of the wire harness becomes cumbersome and assembling workability deteriorates
Solution Approach 1:
The patent divides the assembly into two independent parts: the front frame assembly (containing light source unit, aiming mechanism, and wire harness) and the rear cover. By segmenting the assembly process, the wire harness is routed and fixed on the front frame side before assembly, eliminating the need to handle the wire harness during the final assembly step, thus improving assembling workability while maintaining ease of operation.
2Productivity
If the light source unit and aiming mechanism are integrated on the front frame using a stay, then assembling workability is improved, but the device structure becomes more complex
Solution Approach 1:
The patent merges the light source unit, aiming mechanism, and wire harness into a single integrated front frame assembly. By combining these components on the front frame side before assembly, the patent improves productivity as the integrated assembly can be pre-assembled and tested separately, then installed as one unit, reducing overall assembly complexity despite the integrated structure.
3Force
If the fixing portion is disposed on the upper portion of the stay, then the load on the electrical harness due to twisting is reduced, but the fixing position becomes more constrained
Solution Approach 1:
The patent applies local quality by specifically positioning the fixing portion on the upper portion of the stay, creating a localized optimal fixing point. This localized positioning reduces the twisting load on the wire harness by placing the fixation point where it naturally follows the harness routing path, while the overall design maintains adaptability through the modular front frame assembly that can be installed in standard positions.
Data Source
AI summary
A headlight is provided with a light source unit, an aiming mechanism which can adjust aiming with respect to the light source, a headlight cover which is arranged in front of the light source, and a housing which, by fitting with the headlight cover, covers the light source unit and the aiming mechanism. Inside of the headlight, and between the headlight cover and the light source unit, a stay is provided for arranging the light source unit and the aiming mechanism on the headlight cover.