3D Sleeve Guide for Wiring Harness Breakout Trajectory Control
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Solution Overview
Problem
Complex electrical wiring harnesses often require manual assembly on 2-dimensional form boards, leading to variability and inconsistency in the 3-dimensional routing of breakouts, which can result in suboptimal packaging and interference with machine components.
Innovation Solution
A one-piece sleeve guide with incoming and outgoing guide tubes and a plurality of breakout guide tubes that fix the outgoing trajectories of electrical lines in a 3-dimensional pattern, ensuring consistent divergence from the main trunk and reducing manual assembly variability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly on 2-dimensional form boards is used, then assembly flexibility is maintained, but routing consistency and 3-dimensional positioning precision deteriorate
Solution Approach 1:
The patent introduces a 3-dimensional form board as an intermediary tool between the manual assembly process and the final wiring harness product. This form board provides pre-configured guide tubes that act as mediators to direct wires along precise 3-dimensional paths, ensuring routing consistency while maintaining the benefits of manual assembly flexibility.
Solution Approach 2:
The form board is prepared in advance with guide tubes positioned in the exact 3-dimensional configuration needed for the final product. This preliminary action of pre-positioning the guiding structure eliminates the need for repeated manual positioning during assembly, ensuring consistent routing without increasing assembly complexity.
2Productivity
If manual placement and organization of individual wires is used, then adaptability to design changes is maintained, but assembly time and productivity deteriorate
Solution Approach 1:
The patent segments the wiring harness assembly process into two distinct phases: (1) assembly on the 3-dimensional form board with guide tube support for high-speed initial routing, and (2) post-assembly modifications that can be made to individual wires or bundles. This segmentation allows most of the assembly to benefit from the speed of guided routing while preserving the ability to make adaptive changes when needed.
Solution Approach 2:
The patent transitions from traditional 2-dimensional form boards to 3-dimensional form boards with vertical and angular guide tubes. This dimensional enhancement allows wires to be routed in three-dimensional space, reducing the need for manual adjustment and increasing assembly speed while still allowing flexibility for design changes through the modular guide tube structure.
3Volume of moving object
If 2-dimensional form board routing is used, then simplicity of the guiding structure is maintained, but packaging efficiency and space utilization deteriorate
Solution Approach 1:
The patent employs 3-dimensional form boards with guide tubes extending in multiple directions including vertical and angular orientations. This three-dimensional routing capability allows wires to be packaged more efficiently in the final product by utilizing space in all three dimensions rather than being constrained to a flat 2-dimensional plane, thereby improving packaging efficiency and space utilization.
4Manufacturing precision
If manual assembly without fixed guide tubes is used, then ease of operation is maintained, but routing precision and repeatability deteriorate
Solution Approach 1:
The guide tubes attached to the form board serve as intermediaries that physically guide the wires along precise trajectories. These tubes act as mediators between the assembler's hands and the wires, ensuring that each wire follows the exact intended path without requiring complex manual positioning techniques, thereby maintaining ease of operation while achieving high routing precision.
Solution Approach 2:
The patent replaces the reliance on manual dexterity and visual estimation with a mechanical guidance system consisting of guide tubes. This substitution of the mechanical guidance mechanism for manual positioning ensures repeatable, precise routing trajectories while actually simplifying the operation by providing physical constraints that guide wire placement.
Data Source
AI summary
An electrical wiring harness assembly includes a wiring harness formed by bundled electrical lines, and including breakouts diverging from a main trunk. A sleeve guide encloses a compound junction formed by the main trunk and the breakouts and includes a plurality of breakout guide tubes receiving the plurality of breakouts and fixing outgoing trajectories of the plurality of breakouts from the main trunk in a 3-dimensional pattern where the outgoing trajectories all differ, relative to the center axis of the sleeve guide, in at least one of a longitudinal, a circumferential, or an angular aspect.