Low-Profile Snap-On Cable Mount for Heavy-Truck Frame Routing
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Solution Overview
Problem
There is a need for a space and weight-saving cable routing method in heavy-duty trucks that is low-cost, easy to install, easy to remove for maintenance, and can withstand harsh environments and vibrations, while accommodating larger cables and batteries positioned further from the motors compared to passenger vehicles.
Innovation Solution
A multi-position snap on mount assembly comprising a base with a securement flange and a mating flange, and a mount component with a latch arm and cable receiving member, allowing secure attachment to a vehicle frame for routing cables, with features like latch windows and cable spacer arms for easy installation and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable routing methods are used in heavy duty trucks, then cables can be routed securely, but space and weight increase significantly
Solution Approach 1:
The cable routing system is divided into modular clamp assemblies that can be independently positioned and secured along the cable path. Each clamp is a separate unit that can be attached to the vehicle frame at multiple locations, allowing flexible cable routing without requiring a single heavy-duty routing structure throughout the vehicle.
Solution Approach 2:
The cable clamps utilize a low-profile design with thin-walled construction that provides sufficient structural integrity for securing cables while minimizing material usage. The clamps feature a flexible attachment mechanism that allows them to conform to different frame geometries without requiring thick, heavy materials.
2Reliability
If traditional cable routing methods are used in heavy duty trucks, then cables can be routed securely, but space consumption increases
Solution Approach 1:
The cable routing system transitions from traditional three-dimensional cable trays or conduits that occupy significant volume to a two-dimensional planar arrangement where cables are secured directly to the vehicle frame surface using thin-profile clamps. This reduces the vertical and depth dimensions of the routing structure while maintaining cable security.
Solution Approach 2:
The clamps are designed with a low-profile thin-walled construction that minimizes the volume occupied by the routing structure while providing sufficient strength to secure cables reliably. The thin-film approach allows cables to be routed close to the vehicle frame surface rather than requiring bulky routing enclosures.
3Reliability
If heavy duty cable routing structures are used, then cables can withstand harsh environments and vibrations, but installation and removal become difficult
Solution Approach 1:
The clamp assembly incorporates a dynamic quick-release mechanism that transitions between locked and unlocked states. The latch arm can be easily actuated to release the cable clamp from the frame mounting points, allowing rapid installation and removal without requiring tools or complex disassembly procedures, while maintaining secure attachment during normal operation.
Solution Approach 2:
The cable routing system is divided into independent, modular clamp units that can be installed and removed individually. Each clamp is a self-contained assembly with its own mounting mechanism, allowing maintenance personnel to access and service specific cable sections without disturbing the entire routing system, thereby simplifying installation and removal operations.
4Ease of operation
If modular snap-on mount assemblies are used, then installation and removal are easy, but structural strength may be compromised
Solution Approach 1:
The latch mechanism incorporates a spring-loaded or cam-actuated locking system that provides high clamping force when engaged, ensuring strong mechanical attachment. The dynamic locking mechanism maintains consistent contact pressure on the cable clamp, preventing detachment during vibration and harsh conditions, while allowing rapid release when actuated.
Solution Approach 2:
The mount assembly combines multiple functions into a single integrated component: the clamp body, the latch mechanism, and the mounting interface are merged into one piece. This eliminates weak points that would arise from multiple separate fasteners or connection elements, thereby maintaining high structural strength while preserving ease of installation through the single-action latch release.
Data Source
AI summary
A mount assembly designed to secure cables to a vehicle frame. The mount assembly includes a base and a mount component based on the base. The base has a securement flange and a mating flange with a latch window. The mount component has an attachment member and a cable receiving member. The attachment member has a latch arm with a latch extending therefrom. The latch engages the latch window of the mating flange to secure the mount component to the base.