Self-Shaping Metallic Shield Pipe for Vehicle Wire Harness Routing
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Solution Overview
Problem
Conventional wire harnesses for electric drive systems in vehicles require significant time for routing due to the need for multiple fixing points, which increases costs and complexity, while also lacking efficient electromagnetic noise shielding and protection from external impacts.
Innovation Solution
A wire harness with metallic pipes that maintain their bent shape and are integrated along vehicle body piping, reducing the number of fixing points and providing effective electromagnetic shielding, where the pipes are jointly fastened with fixing members and connected to conductive vehicle body portions for noise dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple fixing points are used to route wire harness in vehicle body, then routing stability is improved, but routing time and workability deteriorate
Solution Approach 1:
The wire harness is divided into multiple independent harness units, each with its own support member. This segmentation allows each unit to be installed independently with fewer fixing points, reducing overall routing time while maintaining stability through the distributed support structure.
Solution Approach 2:
The support members are pre-formed with bent shapes that conform to the vehicle body contours before installation. This preliminary shaping eliminates the need for on-site bending and adjustment, significantly reducing routing time while ensuring proper fit and stability.
2Reliability
If multiple fixing members are used to secure pipe to piping, then fixing reliability is improved, but cost and device complexity deteriorate
Solution Approach 1:
The support member integrates multiple functions: it provides structural support, defines the routing path, and serves as the fixing element itself. This merging of functions eliminates the need for separate fixing members, reducing component count and complexity while maintaining reliable attachment to the vehicle body.
Solution Approach 2:
The support member is designed as a universal component that can be attached to various vehicle body locations and conforms to different routing paths. Its multi-functionality allows it to replace multiple specialized fixing members, simplifying the overall system while ensuring reliable fixation.
3Stability of the object's composition
If pipe rigidity is increased to maintain bent shape, then shape stability is improved, but piping cost and weight deteriorate
Solution Approach 1:
The support member is pre-bent to the exact shape required for the routing path before installation. This preliminary action allows the use of lighter gauge material that would otherwise lack the rigidity to maintain the bent shape, reducing weight while preserving shape stability through the pre-formed geometry.
Solution Approach 2:
The support member uses material and cross-sectional parameters optimized for the specific routing requirements rather than universal high-rigidity specifications. By changing parameters like wall thickness and material composition to match actual load requirements, weight is reduced while maintaining sufficient shape stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution significantly improves routing workability, reduces costs by minimizing fixing members, and provides robust electromagnetic shielding and protection from external impacts, eliminating the need for additional noise release mechanisms.
Implementation Method 1
a shield member having the function of shielding electromagnetic noise
Implementation Method 2
a binding member having conductivity and fixing the pipe to a conductive portion of the vehicle body
Data Source
AI summary
There is provided a wire harness and a manufacturing method thereof. A wire harness routed in a vehicle body is provided with an electric wire and a metallic shield pipe in which the electric wire is inserted. The shield pipe has a rigidity that enables self-maintenance of an after-bent shape. The shield pipe is bent with the electric wire being inserted therein so as to form the shield pipe in a shape conforming to piping to be assembled to the vehicle body.