Non-Circular Clamp Mark for Wire Harness Orientation
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Solution Overview
Problem
Existing electric wire integrated clamp marks fail to regulate the orientation of electric wires during assembly and are prone to twisting due to vibrations after installation, which can lead to reduced electrical conductivity and mounting challenges.
Innovation Solution
An electric wire integrated clamp mark with a non-circular, line-symmetric shape and reduced-thickness portions, featuring a rib on the outer surface, is molded integrally with the wire to prevent rotation and ensure accurate positioning, using a specialized clamp with a non-circular inner shape to secure the wire harness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a circular cross-section clamp mark is used, then the manufacturing is simpler and the wire can be freely oriented, but the wire rotation direction cannot be regulated and the wire may twist due to vibrations
Solution Approach 1:
The clamp mark is designed with a non-circular cross-section (oval, rectangular, or triangular shape) to eliminate rotational symmetry. This asymmetric geometry allows the clamp mark to be mounted only in a specific orientation, thereby regulating the wire rotation direction and preventing twisting due to vibrations, while the molding process remains relatively simple
2Stability of the object's composition
If the clamp mark is tightly fitted to the wire, then the wire position is stable, but the wire may rotate due to vibrations during vehicle operation
Solution Approach 1:
The non-circular cross-section creates an asymmetric fit between the clamp mark and the clamp member, where the wire is held firmly in position while the asymmetric geometry prevents rotational movement. The wire passes through the clamp mark in a way that maintains positional stability without enabling rotation
Solution Approach 2:
The clamp mark is pre-formed with a specific non-circular cross-section during manufacturing, which preliminarily establishes the correct orientation and prevents rotation before the wire is subjected to vibrations during vehicle operation
3Productivity
If a standard circular clamp is used, then the assembly process is faster, but the electrical conductivity may be reduced due to wire twisting
Solution Approach 1:
The non-circular clamp mark design allows for quick identification and correct orientation during assembly, reducing assembly time while simultaneously preventing wire twisting that would compromise electrical conductivity. The asymmetric shape acts as a built-in guide for proper installation
Solution Approach 2:
The clamp mark is pre-formed with orientation-regulating features during manufacturing, so that during assembly the worker only needs to install it in the correct orientation without complex alignment procedures, maintaining high assembly speed while ensuring wire orientation is controlled
Data Source
AI summary
A clamp mark includes a mark main body and flange parts. The mark main body, is made of resin material by molding, and covers a circumference of an electric wire entirely in a circumference direction of the electric wire at a predetermined position of the electric wire in an axial direction of the electric wire. The flange parts are respectively provided on both end portions of the mark main body in the axial direction of the electric wire so as to project outward in a radial direction of the electric wire from an outer peripheral surface of the mark main body. A cross section of the mark main body, which is perpendicular to the axial direction, is not precise circle.