Shielded Conductive Path With Partial Welding For Bending
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Solution Overview
Problem
The existing shielded conductive paths in vehicles face poor workability due to frictional resistance between electrical wires and the shielding pipe, leading to inefficiencies in manufacturing time, particularly when welding long semi-cylindrical members.
Innovation Solution
A shielded conductive path is created by joining two semi-cylindrical members with a weld only in partial regions, including bends and adjacent linear portions, to reduce the time required for welding and prevent positional shifting and cracking during the bending process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is performed over the entire length of the pipe main body to join the two semi-cylindrical members, then the joining strength and structural integrity are improved, but the manufacturing time increases significantly
Solution Approach 1:
The pipe main body is divided into multiple welding regions along its axial direction. Instead of continuous welding over the entire length, welding is performed only in specific segmented regions, thereby reducing total welding time while maintaining sufficient joining strength where most critical.
Solution Approach 2:
Different regions of the pipe main body are assigned different welding qualities based on their functional requirements. Regions with bends or high-stress areas receive welding for enhanced strength, while straight sections with lower stress requirements have reduced or no welding, optimizing the balance between strength and manufacturing efficiency.
2Adaptability or versatility
If the pipe main body is bent to accommodate installation requirements, then the adaptability to vehicle layout is improved, but cracks and separation may occur at the joining portions
Solution Approach 1:
The two semi-cylindrical members are joined together through welding before the bending process is applied to the pipe main body. This preliminary joining ensures that the structural integrity is established prior to deformation, preventing cracks and separation at the joining portions during subsequent bending operations to accommodate vehicle layout requirements.
3Length of moving object
If the pipe main body is made long to connect distant components, then the coverage range is improved, but the insertion operation becomes difficult due to buckling and frictional resistance
Solution Approach 1:
The pipe main body is divided into multiple semi-cylindrical members that are joined together in segments. This segmentation allows each segment to be more manageable during insertion operations, reducing buckling and frictional resistance while still achieving the required total length to connect distant components like the inverter apparatus and battery.
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 configuration reduces manufacturing time by limiting welding to specific regions, preventing cracks and separation, and maintaining the cylindrical shape of semi-cylindrical members, thus enhancing the efficiency of the shielded conductive path production.
Implementation Method 1
a weld that is provided only in a partial region of the shielding pipe that includes at least the bend in the axial direction, the weld joining the two semi-cylindrical members
Data Source
AI summary
A shielded conductive path, including: a cylindrical shielding pipe that is in a state in which two semi-cylindrical members made of a metal material are joined together, and that is provided with a bend at a portion located in an axial direction; an electrical wire housed in the shielding pipe; and a weld that is provided only in a partial region of the shielding pipe that includes at least the bend in the axial direction, the weld joining the two semi-cylindrical members.