Integrated Wire Harness Bracket with Ground Connectors
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Solution Overview
Problem
The installation of wire harnesses in vehicles, particularly in complex environments like aircraft, is time-consuming and challenging due to the complexity of attaching and grounding multiple wire bundles and components.
Innovation Solution
A bracket system with a conductive body, insulated interface portions, ground connectors, and modular designs allows for pre-assembly of wire harnesses outside the vehicle, including attachment to ground studs and support structures, facilitating efficient installation by reducing the number of components and operations required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wire harnesses are attached and grounded individually during vehicle installation, then proper electrical connections and grounding are achieved, but installation time and complexity increase significantly
Solution Approach 1:
The bracket integrates multiple functions into a single component: mechanical attachment of wire bundles, electrical grounding through integrated ground connectors, and structural support. This merging of attachment and grounding functions into one bracket unit reduces the number of separate operations and components needed during installation.
Solution Approach 2:
The bracket is pre-configured with ground connectors and attachment points before installation. Wire bundles can be pre-attached to the bracket outside the vehicle, and grounding connections are established in advance, so that when the bracket is installed in the vehicle, both mechanical and electrical connections are already in place.
2Reliability
If multiple separate brackets are used for attachment and grounding, then proper mechanical and electrical connections are achieved, but the number of components and installation operations increases
Solution Approach 1:
The bracket combines mechanical attachment features (rack with apertures for cable ties, clamps) and electrical grounding features (ground connectors with studs, washers, and nuts) into a single integrated component, eliminating the need for separate attachment brackets and grounding brackets.
Solution Approach 2:
The bracket serves multiple functions simultaneously: it mechanically attaches wire bundles to the vehicle structure, provides electrical grounding paths, offers structural support for the wire harness, and enables modular assembly. This multi-functionality reduces the total number of components needed in the wire harness installation system.
3Reliability
If wire harnesses are assembled inside the vehicle, then proper installation is achieved, but installation complexity and time increase
Solution Approach 1:
The bracket enables wire bundles to be pre-assembled and pre-grounded outside the vehicle in a controlled environment. The modular bracket assembly can be prepared in advance with all necessary connections established, then simply installed as a complete unit in the vehicle, significantly simplifying the in-vehicle installation process.
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 method reduces installation time and complexity by allowing pre-assembly of wire harnesses with integrated ground connections, minimizing the number of brackets needed and simplifying the attachment process, thereby reducing weight and operational steps.
Implementation Method 1
a conductive body adapted to attach the bracket to the vehicle
Implementation Method 2
The interface portion is conductively insulated from the body
Implementation Method 3
The at least one ground connector is adapted to electrically connect the wire harness to a ground
Implementation Method 4
the body includes a surface treatment preventing oxidation but allowing electric conduction
Data Source
AI summary
A bracket for forming a wire harness assembly prior to installation to a structure of a vehicle includes a conductive body adapted to attach the bracket to the vehicle, an interface portion adapted to attach at least one wire of a wire harness to the body, and at least one ground connector attached to the body. The interface portion is conductively insulated from the body. The at least one ground connector is adapted to electrically connect the wire harness to a ground. A method of forming a wire harness assembly for installation to a structure of a vehicle is also presented.