Wire Harness Tubular Exterior with Concave Vibration Restriction
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Solution Overview
Problem
In hybrid and electric vehicles, the conductive paths within wire harnesses vibrate due to vehicle vibrations, leading to potential damage and puncture from friction with foreign substances, which existing exterior members fail to adequately prevent.
Innovation Solution
A wire harness design featuring a tubular exterior member with a straight portion and concave sections positioned close to the conductive paths, extending along the vehicle underfloor, and supported by symmetrical walls, which restricts vibration and flexing, enhancing rigidity and preventing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the exterior member is made smooth and simple in structure, then ease of manufacture is improved, but vibration restriction capability deteriorates
Solution Approach 1:
The exterior member incorporates concave portions at specific locations (at least in one wall of the straight tubular portion) while maintaining other parts smooth. This local modification provides vibration restriction capability exactly where needed (close to the conductive path) without complicating the entire structure, thus resolving the contradiction between ease of manufacture and vibration restriction capability
Solution Approach 2:
The concave portions introduce curved surfaces into the otherwise linear exterior member structure. These curved concave portions effectively restrict vibration of the conductive path while maintaining manufacturability through standard molding techniques, balancing simplicity and functionality
2Reliability
If the exterior member is made rigid with straight tubular portion, then vibration restriction is improved, but flexibility deteriorates
Solution Approach 1:
The exterior member is divided into distinct functional segments: straight tubular portions with concave portions for vibration restriction, and bent tubular portions for flexibility and routing adaptation. This segmentation allows each segment to perform its specific function optimally without compromising the other
Solution Approach 2:
Rigidity is locally applied only where needed (straight tubular portions with concave portions near conductive paths), while flexibility is maintained in other areas (bent tubular portions). This localized approach resolves the contradiction by providing rigidity exactly where vibration restriction is critical while preserving overall flexibility for installation
Data Source
AI summary
A wire harness includes a conductive path and an exterior member with a tubular shape which covers the conductive path. The exterior member includes a straight tubular portion in which a pair of one wall and the other wall are formed, and the straight tubular portion includes a concave portion in at least the one wall, with the concave portion being positioned close to the conductive path.