Rotating Strain-Relief Clip Assembly for Twisted Cable Bundles
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Solution Overview
Problem
Automotive assembly processes often result in unintentional twisting of cables and hoses, leading to stress on termination connections and potential failure, causing rework delays and increased labor costs.
Innovation Solution
A strain-relief clip assembly with a fixing and mount that allows the fixing to rotate independently relative to the mount, providing resistance to axial and rotational movement, thereby reducing twisting and stress on elongated bundles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the bundle is securely fixed to the vehicle chassis, then the bundle is stable and resistant to movement, but the bundle cannot rotate freely to relieve unintentional twists, causing stress on termination connections
Solution Approach 1:
The mounting structure incorporates a rotational joint that enables the bundle to rotate dynamically within a controlled range. This dynamic capability allows the bundle to relieve unintentional twists by rotating to accommodate stress, while the mounting structure maintains overall stability through its anchored connection to the vehicle chassis. The rotational joint acts as a degrees-of-freedom mechanism that absorbs torsional stress without compromising the secure mounting.
2Reliability
If the bundle is allowed to rotate freely at the secured location, then unintentional twists can be relieved, but the bundle becomes unstable and may move excessively
Solution Approach 1:
The mounting structure implements a controlled rotational mechanism that permits rotation only within specific angular limits. This dynamic constraint allows the bundle to rotate enough to relieve unintentional twists and stress, while the mounting structure's anchored connection and mechanical constraints prevent excessive movement or complete freedom of rotation, thereby maintaining stability.
3Strength
If the fixing is rigidly connected to the mount, then the structure is simple and strong, but the bundle cannot rotate to relieve stress, causing termination connection failures
Solution Approach 1:
The connection between the fixing and mount is transformed from a rigid fixed connection to a dynamic rotational joint. This joint maintains structural strength through its mechanical design while introducing rotational degrees of freedom that allow the bundle to relieve stress. The rotational joint acts as a stress-absorbing mechanism that preserves overall structural integrity while preventing stress concentration at the termination connections.
4Reliability
If a twist correction process is implemented, then termination connection failures can be prevented, but rework delays and labor costs increase
Solution Approach 1:
The rotational capability is built into the mounting structure during the initial installation phase, before any twisting issues can occur. This preliminary design feature proactively prevents the formation of problematic stress conditions by allowing the bundle to rotate and relieve twists as they naturally occur during handling and installation, eliminating the need for subsequent correction work.
Solution Approach 2:
The design accepts that unintentional twists will occur during handling and installation, but converts this potentially harmful condition into a beneficial stress-relief mechanism. By providing a rotational joint, the system allows the bundle to naturally rotate and relieve twists through controlled movement, transforming what would be a problematic condition requiring correction into a self-correcting feature that prevents termination connection failures.
Data Source
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AI summary
Disclosed are strain-relief clip assemblies, which include a fixing portion and/or a mount portion, for providing strain relief to bundles of elongated objects (e.g., cables). In one example, a strain-relief clip assembly includes a fixing and a mount. The fixing is configured to secure onto a bundle and the mount is configured to attach the fixing to a structure. The fixing and the secured bundle are configured to rotate independently relative to the mount to provide resistance to axial and rotational movement to the bundle, which may be, in some instances, caused by the inadvertent mishandling of the bundle (e.g., wiring harness) during an installation process. Additionally, the utilization of the disclosed strain-relief clip assemblies may decrease cable rotation and twisting that is caused by vibration, which can provide a strain relief solution for high-speed data cables for sensors, cameras, radars, and the like.