Motor Vehicle Lighting Device Self-Holding Harness Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The assembly of motor vehicle lighting devices, such as headlamps, is complicated due to the need to manually hold and screw a control device into the housing while also managing a connection harness, leading to ergonomic issues and reduced productivity.
Innovation Solution
The lighting device features a housing with an orifice for the connection harness and ribs that lock the male connector in position, allowing the harness to hold itself, freeing the operator's hands to focus on assembling the control device, and additional features like retaining clips enhance stability and ease of assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the control device is manually assembled in the housing by pushing it from the outside while holding the connection harness inside, then the control device can be installed, but the assembly process becomes complicated and time-consuming
Solution Approach 1:
The connection harness is pre-installed in the housing through the orifice before the control device is assembled. This preliminary action allows the harness to be held in place by the housing structure itself, eliminating the need for the operator to hold it manually during the subsequent control device installation.
Solution Approach 2:
The orifice in the housing serves as an intermediary element that allows the connection harness to pass through and be positioned inside the housing before the control device is installed. This intermediary structure enables the harness to be secured without requiring manual holding during assembly.
2Ease of manufacture
If the operator holds the connection harness with one hand and pushes the control device with the other, then the assembly can be completed, but the ergonomics deteriorate due to poor posture
Solution Approach 1:
The housing structure with the orifice and internal positioning features enables the connection harness to hold itself in place without requiring manual support. The harness is retained by the housing geometry and any retaining clips or engagement features, allowing the operator to assemble the control device with both hands free, thus improving ergonomics.
3Ease of repair
If the control device is made replaceable with a female connector, then the device can be maintained, but the assembly complexity increases due to the need to manage the connection harness
Solution Approach 1:
The connection harness is pre-installed and secured in the housing through the orifice before the control device with its female connector is assembled. This preliminary positioning of the harness simplifies the overall assembly process despite the replaceable connector design, as the harness is already in place to receive the connector.
Data Source
AI summary
A lighting device for a motor vehicle, the lighting device including: a housing; a light module arranged inside the housing; a control device designed to control the electrical supply to the light module, including a female connector mounted outside the housing; a connection harness connected to the light module and including a male connector designed to be connected to the female connector of the control device so as to connect the control device electrically to the light module, characterized in that the housing includes: an orifice for the passage of the connection harness from the inside to the outside of the housing; and at least two ribs defining a receiver to receive and lock the male connector in position on the housing.