Resin Wire-Harness Packaging Member with Molded Attachment Protrusions
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Solution Overview
Problem
The existing wire-harness packaging systems for high voltage applications in hybrid and electric cars require manual labor and specialized jigs to set the attachment position of clamps, which is inefficient and prone to misalignment.
Innovation Solution
A wire-harness packaging member made of resin with integrated attachment portions that extend in the circumferential and tube axis directions, featuring convex or strip-shaped protrusions, which serve as setting positions for clamps, eliminating the need for manual labor and jigs by providing a clear attachment point and preventing misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a metal pipe is used as a packaging member with a clamp fitted to the outer peripheral surface, then the packaging member can be fixed to a predetermined position of a vehicle body, but manual labor to decide the attachment position by use of a jig is required
Solution Approach 1:
The attachment position is predetermined during the molding process by forming protrusions directly on the packaging member. This preliminary action eliminates the need for manual positioning and jig-based measurement during assembly, thereby improving workability while maintaining attachment accuracy
Solution Approach 2:
The packaging member itself provides the attachment position indicators through integrated protrusions, allowing the component to define its own attachment locations without external jigs or manual intervention. This self-service approach resolves the contradiction by making the system self-configuring
2Manufacturing precision
If manual labor is required to measure a distance from a reference position and decide the attachment position of the clamp, then the attachment position can be determined, but special jigs and measurement tools are required
Solution Approach 1:
The attachment positions are predetermined and physically marked by protrusions formed during the molding process. This eliminates the need for measurement tools and jigs, reducing device complexity while maintaining precise attachment positioning through the pre-formed geometric features
Solution Approach 2:
The function of external jigs and measurement tools is extracted and integrated directly into the packaging member through the molded protrusions. This consolidation eliminates separate devices while preserving positioning precision
3Ease of operation
If an attachment portion is formed integrally with the tube body when molded out of resin, then the attachment position can be clearly identified and workability is improved, but the structure becomes more complex
Solution Approach 1:
The attachment portions (protrusions) are merged with the tube body through integral molding, creating a unified structure. This combining of functions into a single molded component improves workability by providing clear attachment indicators while the integration actually reduces overall structural complexity compared to separate parts
4Weight of moving object
If the packaging member is made of resin instead of metal, then the weight is reduced and cost is decreased, but the rigidity and chipping resistance may be compromised
Solution Approach 1:
The packaging member uses resin material with locally optimized properties - the main tube body provides lightweight protection while integrated attachment portions with protrusions provide localized rigidity and chipping resistance at critical stress points, achieving both weight reduction and structural performance
Data Source
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AI summary
A wire-harness packaging member (16) has a setting portion (27) in the attachment position of a post-fitted part (32) attached to the wire-harness packaging member (16) on the outer surface of the wire-harness packaging member (16).