Wire Harness Bellows Sheath Impact Absorption
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Solution Overview
Problem
Existing wire harnesses for hybrid and electric vehicles face issues with cracking due to the inability of straight portions to absorb and distribute impact forces from flying stones, leading to degradation in assembly ease and increased cracking risks.
Innovation Solution
Incorporating a bellows-shaped portion within the straight portion of the sheath member, which is wavy in the tube circumferential direction, enhances flexibility to absorb impact while maintaining sufficient rigidity to prevent bending and cracking, thereby reducing the likelihood of damage from flying stones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the straight portion has high rigidity to suppress bending, then the ease of assembling the wire harness is improved, but the ability to absorb and distribute impact force from flying stones deteriorates, leading to cracking
Solution Approach 1:
The bellows-shaped portion is formed only in a specific region of the straight portion (the portion more likely to contact flying stones), while other regions maintain high rigidity. This local differentiation allows the bellows-shaped region to absorb impact through its flexible, expandable structure, while the rest of the straight portion maintains sufficient rigidity for easy assembly and structural support.
2Reliability
If the straight portion is made flexible to absorb impact, then the ability to absorb and distribute impact force is improved, but the rigidity to suppress bending and maintain assembly ease deteriorates
Solution Approach 1:
The straight portion is segmented into different functional regions: a bellows-shaped portion with high flexibility for impact absorption, and other portions maintaining high rigidity for structural support and easy assembly. This segmentation allows each region to perform its specific function optimally without compromising the overall performance of the wire harness.
3Reliability
If the bellows-shaped portion is made more flexible to absorb impact, then the impact absorption capability is improved, but the rigidity in the tube axial direction deteriorates, causing excessive bending
Solution Approach 1:
The bellows-shaped portion incorporates a wave-like curvature in the tube circumferential direction, which allows it to expand and contract radially to absorb impact forces. This curved structure is designed to maintain sufficient rigidity in the axial direction while providing flexibility in the radial direction for impact absorption.
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
The bellows-shaped portion effectively distributes impact forces, reducing the possibility of cracking and maintaining assembly ease by providing both flexibility and rigidity, thus enhancing the durability and installation simplicity of the wire harness.
Implementation Method 1
the bellows-shaped portion is more flexible than a portion of the straight portion other than the bellows-shaped portion. As a result, even if a flying stone comes into contact with a portion of the bellows-shaped portion, the bellows-shaped portion more flexible than other portions is capable of absorb impact of the flying stone
Data Source
AI summary
A wire harness is provided with an electrically conductive path, and a tubular sheath member into which the electrically conductive path is inserted. The sheath member includes a straight portion having strength to limit bending. A bellows-shaped portion which is wavy in shape in a tube circumferential direction, is formed in a portion of the straight portion in a sectional view. The bellows-shaped portion is more flexible than a portion of the straight portion other than the bellows-shaped portion.