Round Cable Assembly with Non-Rotational Support Clip
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Solution Overview
Problem
Existing electronic modules for vehicles require complex and costly assembly processes due to the need for precise rotational alignment and secure mounting of round cables with multiple wires, which complicates the manufacturing and mounting of these modules in large numbers.
Innovation Solution
A design featuring a circuit board with predetermined holes and a round cable with a support clip and body that fixes the wires in a non-rotational manner, allowing for simple and automated assembly by deflecting the wires into a predetermined pattern for secure electrical contact, utilizing a support clip and body configuration that prevents rotation and ensures correct angular orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If round cables with multiple wires are used for signal transmission, then signal transmission capability is improved, but assembly complexity and mounting difficulty increase
Solution Approach 1:
The cable assembly is segmented into distinct functional components: a support clip for mechanical fixation, a body for structural support, and multiple wires for signal transmission. This segmentation allows each component to be optimized independently and simplifies the overall assembly process.
Solution Approach 2:
The support clip and body are pre-configured with fixing elements and engagement features that automatically align and secure the wires in the correct positions before final assembly. This preliminary arrangement eliminates the need for complex rotational alignment during mounting.
2Manufacturing precision
If precise rotational alignment is required for cable mounting, then electrical contact precision is improved, but assembly time and production cost increase
Solution Approach 1:
The support clip and body feature asymmetric fixing elements and engagement structures that provide a unique, non-rotational alignment. This asymmetric design ensures that the wires can only be inserted in the correct orientation, eliminating rotational alignment issues while maintaining precise electrical contact.
Solution Approach 2:
The fixing elements and engagement features are designed to automatically self-align and self-secure the wires in the correct positions during assembly. The non-rotational fixing mechanism self-corrects any misalignment, eliminating the need for manual rotational adjustment and reducing assembly time.
3Reliability
If complex mounting procedures are used to secure cables, then mounting reliability is improved, but ease of manufacture decreases
Solution Approach 1:
The support clip and body are merged into a integrated assembly that combines mechanical fixation and structural support functions. This merging simplifies the manufacturing process by reducing the number of separate components and assembly steps while maintaining mounting reliability through the combined fixing elements.
Solution Approach 2:
The support clip and body are designed as simple, inexpensive plastic components that can be easily manufactured and replaced if necessary. This approach prioritizes ease of manufacture and cost-effectiveness while maintaining sufficient reliability for the application.
4Extent of automation
If wires are arranged in predetermined patterns, then assembly automation is improved, but device complexity increases
Solution Approach 1:
The wires are pre-arranged in their final predetermined pattern within the body before the assembly process begins. The support clip and fixing elements are designed to maintain this pattern automatically, enabling direct transfer to automated assembly equipment without requiring complex positioning mechanisms.
Solution Approach 2:
The body and support clip are designed as universal components that can accommodate different wire configurations and patterns while maintaining the same basic structure and assembly process. This multi-functionality allows the same component design to work with various wire arrangements, simplifying automation.
Data Source
AI summary
An electronic module includes a circuit board having three first holes arranged therein in a predetermined pattern, and a cable having at least three wires, a support clip and a body. The three wires are arranged around a longitudinal axis of the cable. The support clip has a fixing element arranged radially outside the wires. The wires are held by the fixing element in such a way that the support clip is fixed in a non-rotational manner relative to the wires. The cable is configured in such a way that the support clip is connected in a non-rotational manner to the body with respect to the longitudinal axis, and that a course of the wires is deflected by the body in such a way that the ends of the wires are positioned in the predetermined pattern. Conductors of the wires are disposed in the first holes.