Wire Harness Braid Widening for Core Insertion
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Solution Overview
Problem
The difficulty in inserting a core into a long braid for crimping operations in wire harness production, especially when the braid is longer than the opening of the exterior member, affects workability due to the challenge of accessing the core from the other end.
Innovation Solution
A method that involves forming a widely open braided mesh portion by widening the braid close to the end of the exterior member, allowing the core to be inserted from the outside through this mesh for easier crimping, and using a convex insertion side to facilitate smooth insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a long braid is used to cover conductive path terminal portions led far from the exterior member end, then shielding coverage is improved, but core insertion difficulty increases
Solution Approach 1:
The braid is designed with a dynamic characteristic allowing it to be expanded into a bell shape during the crimping process. This temporary expansion creates a wide opening that facilitates easy core insertion, while the braid returns to its normal cylindrical shape after crimping to provide adequate shielding coverage. The dynamic transformation resolves the contradiction between maintaining long braid length for shielding and enabling easy core insertion.
Solution Approach 2:
The crimping operation is performed as a preliminary action before final assembly, creating the expanded bell shape that facilitates subsequent core insertion. By preparing the braid in this expanded state beforehand, the process enables easy core insertion while maintaining the long braid length needed for proper shielding coverage of conductive paths led far from the exterior member end.
2Reliability
If the braid length is increased relative to the exterior member opening dimension, then shielding effectiveness is improved, but crimping operation difficulty increases
Solution Approach 1:
The braid utilizes dynamic expansion during crimping, transforming from a compact cylindrical shape to an expanded bell shape. This dynamic behavior allows long braids to be easily crimped onto the exterior member by creating temporary space for core insertion, while maintaining the full length necessary for effective shielding after the crimping operation is complete.
Solution Approach 2:
The physical state of the braid is changed during the crimping process through parameter transformation. The braid transitions from a tight braided configuration to an expanded state with increased volume and opening dimension, facilitating core insertion. After crimping, the braid returns to its original configuration, maintaining both the long length for shielding effectiveness and the ability to be properly secured during manufacturing.
Data Source
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AI summary
Disclosed is a method for producing a wire harness including a core inserting step of forming a widely open braided mesh portion (34) by widening a braided mesh (28) of a braid (17) before crimping is performed, and of inserting a core (35) into an end (20) from the outside of the braid (17) via the widely open braided mesh portion (34).