Self-Aligning Pass Through Plate for Vehicle Panel Installation
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Solution Overview
Problem
Conventional pass through plates in vehicles are cumbersome and time-consuming to install due to the weight and tension of pre-connected wiring harnesses, requiring manual alignment and support by a single technician, making the process awkward and inefficient.
Innovation Solution
The pass through plate design features upper and lower retaining elements that project outwardly from the body, allowing for self-alignment and pivoting during installation, enabling the plate to be securely attached to a vehicle panel or pedal plate with minimal technician effort, using the plate's weight and wiring harness to facilitate attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional pass through plates are used with pre-connected wiring harnesses, then electrical elements can be passed through the plate, but the installation process becomes awkward and time-consuming due to the weight and tension of the wiring harness requiring manual alignment and support
Solution Approach 1:
The pass through plate is divided into multiple sections with retaining elements positioned at different locations. These retaining elements segment the installation process into manageable steps, allowing the plate to be attached progressively rather than requiring complete manual alignment and support throughout the entire installation process.
Solution Approach 2:
The retaining elements are pre-formed as integral parts of the pass through plate body during manufacturing. This preliminary action eliminates the need for separate alignment and support operations during installation, as the retaining elements are already in place to guide and secure the plate during the attachment process.
2Productivity
If a single technician performs the installation, then labor costs are reduced, but the installation process becomes more difficult and time-consuming due to the need for manual alignment and support
Solution Approach 1:
The pass through plate is designed to be self-aligning through its retaining elements, which automatically guide the plate into proper position during installation. This self-service mechanism eliminates the need for a second technician to provide manual alignment and support, making the installation process easier for a single technician while maintaining high productivity.
Solution Approach 2:
The retaining elements are designed with dynamic characteristics that allow them to flex and adapt during installation, accommodating the weight and tension of the wiring harness. This dynamic design enables a single technician to manage the installation process more easily without compromising installation efficiency.
3Reliability
If the pass through plate includes mounting holes for attachment, then the plate can be securely fixed to the vehicle panel, but the alignment of mounting holes with panel holes becomes a time-consuming manual process
Solution Approach 1:
The mounting process is segmented into multiple stages using retaining elements positioned at different locations on the plate. The first retaining element secures the upper portion while the second retaining element secures the lower portion, dividing the complex alignment task into simpler, sequential steps that reduce overall process complexity while maintaining secure mounting.
Solution Approach 2:
The retaining elements act as intermediary components between the pass through plate and the vehicle panel. These intermediaries facilitate the alignment process by providing reference points and mechanical guidance, making the alignment of mounting holes less complex while ensuring reliable securement of the plate to the panel.
Data Source
AI summary
Pass through plates comprise a body with an opening between opposed first and second surfaces for accommodating the passage of electrical elements. One or more upper retaining elements project outwardly from the body and are positioned adjacent a body top portion. One or more lower retaining elements project from the body and are positioned adjacent a body bottom portion. The upper and lower retaining elements are each configured to both engage respective top and bottom sections of an opening in an external object, and to engage a backside surface of the external object when installed within the opening to retain the pass through plate for attachment with the external object. The upper and lower retaining elements are positioned to enable movement of the pass through plate from an upward position in the opening to a downward position in the opening for fixed attachment with the external object.