Movable Clamp for Shielded Cable Installation
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Solution Overview
Problem
The installation of wire harnesses in vehicles, particularly in electric and hybrid cars, is challenging due to the rigidity of shielded cables with large diameters, requiring significant force and skill to connect terminals to terminal blocks, as the fixed portions near the ends limit the degree of freedom and length, making smooth connection operations difficult.
Innovation Solution
A wire harness design featuring a clamp that can be moved along the power supply shielded cables, allowing sufficient length for easy connection of terminals to the terminal box before being fixed, and a method where the clamp is initially positioned away from the connection terminals to provide the necessary flexibility for easy insertion and then securely attached, ensuring the cables are held in a spaced-apart configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the clamp is fixed near the end portions of the shielded cables to secure them against movement, then the cables are held in a stable position, but the degree of freedom and length for bending the cable ends to connect terminals is reduced, making connection operations difficult
Solution Approach 1:
The clamp is designed to be movable along the shielded cables before fixation, allowing the installer to temporarily position and adjust the cables to the optimal configuration for terminal connection. After the connection is made, the clamp is then fixed to secure the cables in their final stable position. This preliminary adjustment phase resolves the contradiction by providing both flexibility during installation and stability after installation.
Solution Approach 2:
The clamp transitions from a dynamic state (movable along the cables) to a static state (fixed in position). During the installation phase, the clamp's mobility allows it to be positioned optimally for terminal connection operations. Once the connection is complete, the clamp is fixed to provide stable cable positioning. This dynamic-to-static transition resolves the contradiction between ease of operation and reliability of fixation.
2Reliability
If the shielded cables are made with large diameter and high rigidity to handle high voltage and large current, then the electrical performance is improved, but the cables become difficult to bend and require significant force and skill for installation
Solution Approach 1:
The movable clamp acts as an intermediary tool that facilitates the installation of rigid shielded cables. By allowing the clamp to move along the cables before fixation, it provides a mechanical advantage that enables easier positioning and bending of the rigid cables during installation, while maintaining their high rigidity and electrical performance for handling high voltage and current.
Solution Approach 2:
The installation process utilizes parameter changes in the clamp's position along the cable length. By varying the clamp's position before fixation, the installer can optimize the cable's bending radius and positioning to match the terminal connection requirements, thereby reducing the force and skill needed to install rigid high-voltage cables while maintaining their electrical performance.
3Ease of manufacture
If the clamp is fixed in a predetermined position to secure the cables, then the installation layout is standardized, but the connection operation cannot be smoothly carried out due to insufficient length and flexibility
Solution Approach 1:
The clamp is designed to be positioned and adjusted preliminarily before the final fixation step. During this preliminary phase, the installer can optimize the cable routing and positioning to ensure smooth connection operations. After the connection is made, the clamp is then fixed in its predetermined position, achieving both standardized installation layout and smooth connection operations.
Solution Approach 2:
The clamp transitions from a dynamic positioning phase to a static fixed position. During the dynamic phase, the clamp can be moved to optimize cable positioning for connection operations. Once the connection is complete, the clamp is fixed in the predetermined position, achieving standardization. This dynamic-to-static transition resolves the contradiction between standardization and operational smoothness.
Data Source
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AI summary
A wire harness includes a cable and a clamp. The cable has an end portion at which a connection terminal is provided. The connection terminal is electrically connected to a connecting portion. The clamp is attached with the cable so as to be movable with respect to the cable in a direction in which the cable extends. The clamp is fixed to a fixing portion disposed adjacent to the connecting portion in a state that the connection terminal is electrically connected to the connecting portion.