Wire Harness Routing Structure for Compact Protector Bending
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Solution Overview
Problem
Conventional wire harness installation structures for motor vehicles require large protectors to control deflection during bending and extending, which are costly and inefficient in terms of space usage.
Innovation Solution
A wire harness installation structure with a bending motion mechanism that includes a first portion fixed to a protector, a second portion and a third portion offset from the imaginary straight line connecting the first and second portions, where the second and third portions are fixed on a movable member, allowing the wire harness to bend with a shorter excess length between the second and third portions compared to the first and third portions, thereby reducing the bending interval and enabling miniaturization of the protector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a large protector is installed to control deflection of the wire harness during bending and extending, then the wire harness can be protected from damage and interference, but the cost increases and storage space and installation space are required
Solution Approach 1:
The wire harness is divided into three portions (first, second, and third portions) with different routing configurations. The third portion is offset from the straight line connecting the first and second portions, creating a predetermined bending path that naturally controls deflection without requiring a large protector
Solution Approach 2:
The wire harness is routed in a three-dimensional configuration where the third portion is offset in the bending movement direction from the imaginary straight line. This spatial arrangement creates a compact bending interval that reduces the required protector size while maintaining protection effectiveness
2Reliability
If a large protector is installed to control deflection of the wire harness, then the wire harness can be protected, but the cost increases
Solution Approach 1:
The wire harness is segmented into three portions with the third portion offset to create a natural bending path. This segmentation allows the use of a smaller, more cost-effective protector while maintaining adequate protection against damage and interference
Solution Approach 2:
The offset routing of the third portion creates a self-contained bending mechanism that naturally controls deflection during bending and extending. This self-service approach reduces reliance on large protectors, thereby reducing manufacturing cost
Data Source
AI summary
A wire harness installation structure includes a wire harness, a protector, and a bending motion mechanism that causes the wire harness to make a bending movement. The wire harness has a first portion that is fixed to the protector, a second portion that is distant from both of the first portion and the protector beyond a bending position of the wire harness, and a third portion that is located between the first portion and the second portion. The second portion and the third portion of the wire harness are fixed on a movable member of the bending motion mechanism, and the wire harness is routed so that a second excess length between the second portion and the third portion is shorter than a first excess length between the first portion and the third portion.