Modular Rail Wire Harness Retention Toolless Interlocks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for mounting cable/wire harnesses in vehicles face challenges such as misalignment due to tolerances in clips and sheet metal holes, leading to increased design and tooling costs, long development times, and limited versatility across different vehicle models.
Innovation Solution
A modular rail system with toolless interlocks and adjustable clips that can be easily assembled and adapted to various vehicle designs, using eyelets for tie-down straps and slide tracks for secure mounting, allowing for flexible use across different vehicle configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If uniquely designed plastic channels are created for a particular wire harness branch, then the mounting precision and fit are improved, but the device complexity, design time, and tooling investment increase
Solution Approach 1:
The patent applies universality by designing a standardized plastic channel with universal mounting features that can accommodate multiple wire harness configurations. The channel includes adjustable mounting brackets and universal clip receptacles that can adapt to different hole patterns and routing requirements, eliminating the need for uniquely designed channels for each application while maintaining proper mounting precision
Solution Approach 2:
The patent segments the mounting system into modular components including the plastic channel, mounting brackets, clips, and reinforcement plates. This segmentation allows individual components to be optimized and combined in different configurations, reducing overall system complexity while maintaining manufacturing precision through standardized interfaces
2Adaptability or versatility
If custom channels are designed for specific vehicle models, then the adaptability to specific routing paths is improved, but the productivity and development time decrease
Solution Approach 1:
The patent applies dynamics by incorporating adjustable and reconfigurable mounting features within the plastic channel. The mounting brackets can be positioned at multiple locations, and clips can be installed at various receptacles along the channel length, allowing the same channel design to adapt dynamically to different vehicle model requirements without requiring custom tooling for each model
Solution Approach 2:
The universal plastic channel design serves multiple vehicle models and wire harness configurations through standardized mounting interfaces and flexible routing capabilities, significantly improving productivity by eliminating the need for separate development cycles and tooling investments for each vehicle model
3Ease of operation
If clips are used to mount wire harnesses to sheet metal panels, then the ease of installation is improved, but misalignment occurs due to tolerances, worsening the manufacturing precision
Solution Approach 1:
The patent introduces mounting brackets and reinforcement plates as intermediary components between the clips and the sheet metal panel. These intermediaries provide precision mounting features with tighter tolerances than sheet metal holes, serving as a mediator that eliminates misalignment issues while maintaining the ease of clip-based installation. The brackets can be precisely positioned and secured to the panel, then clips attach to the brackets with accurate alignment
Data Source
AI summary
A modular rail as a wire harness mounting system uses clips and tie straps. Each clip has a clip post engaging a mounting hole and a clip head. The modular rail has a plurality of rail segments sequentially joined by toolless interlocks disposed at each longitudinal end of each rail segment. Each rail segment has a plurality of eyelets at longitudinally-spaced locations for receiving respective tie-down straps adapted to encircle the wire harness. The interlocks have complementary clasp features including a latch tab that deflects to enable engagement of each respective interlock. A bottom surface of each rail segment has a plurality of longitudinally-spaced brackets, each having a slide track configured to secure a clip head along a range of locations on the slide track. A top surface of each rail segment receives the wire harness when the wire harness is secured via the tie-down straps being inserted through respective eyelets.