Meshed Wire Harness Assembly With Eyelet Fasteners for Complex Routing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing wire harness manufacturing processes are costly due to the need for manual assembly of exterior members, especially when wire routing paths are complex or branched, as they require wrapping adhesive tape or inserting wires into corrugated tubes.
Innovation Solution
A wire harness with meshed sheet exterior members that are stacked and joined together, using a method involving a jig plate and eyelet fasteners to automate the assembly process, eliminating the need for manual wrapping or tube insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If adhesive tape is wrapped around the wire or corrugated tube is used to accommodate the wire, then the wire is protected from interference with peripheral parts, but manual assembly is required which increases manufacturing cost
Solution Approach 1:
The exterior member is divided into a body portion and a protruding portion that extends along the wire. This segmentation allows the exterior member to be pre-formed and then automatically assembled to the wire, eliminating the need for manual wrapping of adhesive tape or insertion into corrugated tubes, thereby reducing manufacturing cost while maintaining protection functionality.
Solution Approach 2:
The protruding portion of the exterior member is pre-formed to extend along the wire in the desired routing path. This preliminary preparation enables automatic assembly processes where the exterior member can be directly positioned and fixed to the wire without requiring manual manipulation during assembly, thus reducing manufacturing cost while ensuring proper wire protection.
2Manufacturing precision
If exterior members are manually assembled to stabilize quality, then assembly quality is improved, but manufacturing cost increases
Solution Approach 1:
The exterior member is designed with a protruding portion that automatically positions itself along the wire during assembly. This self-positioning feature ensures consistent assembly quality without requiring manual adjustment, enabling automatic assembly processes that reduce manufacturing cost while maintaining stable assembly quality.
Solution Approach 2:
The exterior member is pre-formed with the protruding portion extending along the wire's routing path. This preliminary configuration ensures that during automatic assembly, the exterior member naturally aligns with the wire, achieving stable assembly quality without manual intervention and thereby reducing manufacturing cost.
3Object-affected harmful factors
If complex routing paths or branched wires are handled with traditional exterior members, then wire protection is maintained, but manual assembly is required increasing cost
Solution Approach 1:
The exterior member is segmented into a body portion and a protruding portion that can extend along complex routing paths. This segmentation allows the protruding portion to follow branched or complex wire paths while maintaining a standardized structure that can be automatically assembled, enabling automation even for complex routing configurations without increasing cost.
Solution Approach 2:
The protruding portion of the exterior member is designed to flexibly extend along the wire's routing path, adapting to complex or branched configurations. This dynamic design allows a single standardized exterior member structure to accommodate various wire routing complexities while enabling automatic assembly processes, thus improving automation extent without sacrificing wire protection.
Data Source
AI summary
A wire harness includes a plurality of exterior members each having a meshed sheet shape with insulating property on an outer surface thereof, and at least one routing wire with a protection target part interposed between a pair of overlapping exterior members, and the plurality of exterior members are stacked and include joints where at least parts of the exterior members are joined together. The joint includes an eyelet fastener that penetrates through the plurality of exterior members and clamps to crimp the exterior members from an exterior member side of one outer layer and an exterior member side of the other outer layer.