Wire Bundle Form Board With Quick Connect Mounting Features

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Solution Overview

Problem

The existing methods for forming and coupling wire bundles to structures are inefficient, requiring multiple form boards and manual installation with metal spanner bars, which occupy space, increase installation time, and add weight to vehicles, reducing fuel efficiency.

Innovation Solution

A fixture with quick connect mounting features and retention straps allows for tool-less installation of wire bundles to a spanner bar, using a common wire bundle form board for multiple configurations and reducing storage needs, and enables closer placement of wire bundles to the structure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If metal spanner bars with nut runners are used to couple wire bundles to structures, then the wire bundles can be securely mounted, but the distance between the structure and wire bundles increases and installation time increases

Engineering Contradiction:

Improvesecure mountingVSAvoidinstallation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The mounting system is segmented into modular components: the spanner bar with integrated mounting features, the wire bundle form board with attachment mechanisms, and the retention straps. This segmentation allows for pre-assembly of the wire bundle form board with mounting features before attachment to the spanner bar, reducing installation time while maintaining secure mounting through the distributed mounting points and retention mechanisms.

Inventive Principle:

Principle #1Segmentation

2Reliability

If metal spanner bars are used to couple wire bundles to structures, then secure mounting is achieved, but the weight of the vehicle increases

Engineering Contradiction:

Improvesecure mountingVSAvoidvehicle weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The invention employs composite material construction for the spanner bar and wire bundle form board components. The spanner bar may be constructed from composite materials that provide sufficient structural strength for secure mounting while reducing weight compared to traditional metal spanner bars. This allows maintenance of reliable wire bundle attachment while decreasing overall vehicle weight.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If multiple form boards are stored for different wire bundle configurations, then various configurations can be produced, but floor space is occupied

Engineering Contradiction:

Improveconfiguration varietyVSAvoidstorage space

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The wire bundle form board is designed with universal, reconfigurable mounting features that can accommodate multiple wire bundle configurations. The form board includes multiple attachment points and adjustable mounting mechanisms that allow the same form board to be configured for different wire bundle arrangements. This eliminates the need to store multiple dedicated form boards for different configurations, freeing floor space while maintaining configuration versatility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Ease of manufacture

If pass throughs are provided in spanner bars for back side access, then fasteners can be installed, but the distance between structure and wire bundles increases

Engineering Contradiction:

Improvefastener installationVSAvoiddistance from structure

Core Design Contradiction:

Ease of manufactureVSLength of stationary object

Solution Approach 1:

Instead of providing pass throughs in the spanner bar for back side access, the invention inverts the approach by providing mounting features on the forward side of the spanner bar that are accessible from the same side as the wire bundles. The wire bundle form board includes integrated mounting features that can be attached to the spanner bar without requiring access to the back side, thereby eliminating the need for pass throughs and reducing the distance between the structure and wire bundles.

Inventive Principle:

Principle #13The other way round (Inversion)

Data Source

PatentUS20220320839A1Apparatus for forming a wire bundle and coupling the wire bundle to a structure

Publication Date: 2022.10.06 THE BOEING CO

AI summary

A wire bundle forming apparatus including a wire bundle form board having a plurality of mounting structure couplings, and at least one wire bundle mounting structure configured to couple with the plurality of mounting structure couplings for removably coupling the at least one wire bundle mounting structure to the wire bundle form board in a predetermined pattern corresponding to a predetermined configuration of a wire bundle. The at least one wire bundle mounting structure has a wire receiving portion. The at least one wire bundle mounting structure is common to both arranging at least one wire in the predetermined configuration for formation of the wire bundle, and, when removed from the wire bundle form board with the wire bundle coupled to the at least one wire bundle mounting structure, a fixture for coupling the wire bundle to a structure.