Wire Harness Branching Circuit Group Design
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Solution Overview
Problem
Existing wire harness manufacturing processes for branch parts require increased man-hours due to the need for different exterior materials and separate waterproof treatments, which complicates the manufacturing process.
Innovation Solution
A wire harness design where the first and second circuit groups share exterior materials between connectors, allowing the second circuit group to branch from the first at the second connector or connection target, enabling simultaneous waterproof treatment with the connector, thus eliminating the need for crossing taping and separate exterior materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different protective members are provided for each wire group up to the branch part, then each wire group can be individually protected, but the manufacturing complexity and time increase
Solution Approach 1:
The patent combines multiple wire groups (first wire group and second wire group) into a single common protective member (first sheath) that covers both groups from the first connector to the branch point. This merging approach provides individual protection for each wire group while simplifying the manufacturing process by eliminating the need to separately handle and protect each wire group with different protective members.
2Reliability
If separate waterproof treatment is applied to the branch part, then waterproof protection is achieved, but manufacturing time and effort increase
Solution Approach 1:
The patent merges the waterproof treatment process by applying a single waterproof coating or treatment to the entire first sheath that covers both wire groups, rather than applying separate waterproof treatments to each wire group and the branch part individually. This combined approach ensures comprehensive waterproof protection while significantly reducing manufacturing time and effort.
3Strength
If the branch part is taped in a crossing manner, then structural support is provided, but additional materials and manufacturing steps are required
Solution Approach 1:
The patent merges the structural support function into the common first sheath by designing it to extend along both wire groups and cover the branch point where the second wire group branches off. This integrated sheath structure provides the necessary structural support at the branch part without requiring additional crossing tapes or separate reinforcement materials, thereby simplifying the manufacturing process.
Data Source
AI summary
A wire harness includes a first circuit group and a second circuit group. The first circuit group has one end connected to a first connector and another end connected to a second connector. The second circuit group has one end connected to the first connector and another end connected to a third connector. The second circuit group branches from the first circuit group at a position of the second connector or at a position of a connection target connected by the second connector.