Printed Wiring Harness Layout for Low-Cost Automated Assembly
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Solution Overview
Problem
The existing wiring harness production processes are complex, costly, and lack automation, making them inefficient and difficult to assemble, particularly for large-scale electrical connections.
Innovation Solution
A method involving conductive ink printing on a substrate to form conductive traces, followed by insulating protection, allowing for rapid and automated production of wiring harnesses with multiple layers and complex electrical loops, and incorporating features like heat sinks and shielding to enhance performance and reduce interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a wiring harness with many branches and connections is designed to meet complex electrical system requirements, then the electrical system functionality and reliability are improved, but the wiring harness structure becomes more complex and the binding work becomes more difficult
Solution Approach 1:
The wiring harness is divided into multiple branch circuits, each serving specific functions. The binding portions are segmented and positioned at different locations along the wiring harness, allowing localized binding operations rather than requiring complete disassembly and reassembly of the entire harness.
Solution Approach 2:
The binding portions are pre-formed and pre-positioned at specific locations along the wiring harness before final assembly. This preliminary preparation of binding structures eliminates the need for complex post-assembly binding work and reduces the risk of connection errors.
2Ease of manufacture
If conventional binding methods are used on disassembled wiring harnesses, then assembly flexibility is improved, but the binding work requires disassembly and reassembly which increases time and labor
Solution Approach 1:
Binding portions are prepared and positioned in advance during the wiring harness assembly process, eliminating the need for subsequent disassembly and reassembly operations. This preliminary binding action maintains assembly flexibility while significantly reducing total binding time.
Solution Approach 2:
The binding process is integrated into the continuous assembly flow rather than being a separate post-assembly operation. Binding portions are applied continuously as the wiring harness is being assembled, eliminating idle time associated with disassembly and reassembly cycles.
3Reliability
If binding portions are added to secure wiring harnesses, then fixation reliability is improved, but the number of components and binding work increase
Solution Approach 1:
Multiple binding functions are merged into integrated binding portions that simultaneously secure multiple branches of the wiring harness. These binding structures combine fastening, positioning, and protection functions into single components, reducing the total number of separate parts needed.
Solution Approach 2:
The binding portions are designed as multi-functional elements that serve multiple purposes: mechanical fastening of wiring branches, electrical insulation, structural support, and organizational alignment. This universality reduces the need for specialized components for each function.
Data Source
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AI summary
The present disclosure provides a wiring harness production method and a wiring harness. The wiring harness production method includes: Step S10: preparing a printing plate; Step S20: preparing a substrate; Step S30: printing conductive ink onto the substrate by means of the printing plate; Step S40: coagulating the conductive ink to form a conductive loop; and Step S50: forming an insulating protective layer around the conductive loop and on a surface thereof. The present disclosure solves the technical problems of complex production process and high processing cost of a wiring harness for electrically connecting electrical components.