Wire Harness Conductor Rigidity Integration
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Solution Overview
Problem
Existing wire harness designs for high-voltage devices in hybrid and electric cars require retrofitted exterior members for route regulation, increasing component count, manufacturing time, and cost.
Innovation Solution
A wire harness design where conductors with varying rigidity are connected and covered with a sheath, eliminating the need for retrofitted exterior members by integrating route regulation into the conductor structure, with high rigidity in specific sections and flexibility in others, and applying forming treatments to ensure consistent diameters for seamless integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If retrofitted exterior members are used for route regulation, then route regulation can be achieved, but the number of components increases and manufacturing cost increases
Solution Approach 1:
The patent merges the route regulation function with the conductor structure itself by creating a multi-section conductor where at least one section has different rigidity characteristics. This integration eliminates the need for separate retrofitted exterior members while maintaining the required route regulation capability, directly resolving the contradiction between achieving route regulation and reducing component count
Solution Approach 2:
The patent applies local quality by creating conductors with spatially varying rigidity properties. Different sections of the conductor have different rigidity characteristics (first rigidity in route regulation sections, second rigidity in other sections), allowing the conductor to provide route regulation only where needed while maintaining flexibility elsewhere, thus eliminating the need for additional exterior members
2Reliability
If retrofitted exterior members are used for route regulation, then route regulation can be achieved, but the number of man-hours for manufacturing increases
Solution Approach 1:
The patent applies preliminary action by pre-forming the conductor with different rigidity sections during the conductor manufacturing process itself, before the wire harness assembly process. The forming treatment is applied to the conductor to create the required rigidity distribution in advance, eliminating the need for additional retrofitted exterior members and the associated manual assembly time
Solution Approach 2:
By merging the route regulation function into the conductor structure through preliminary forming, the patent eliminates the need for separate retrofitted exterior members and their associated installation steps, directly reducing manufacturing time and improving productivity
3Device complexity
If conductors with varying rigidity are connected and covered with sheath, then retrofitted exterior members can be eliminated, but the sheath formation becomes more complex
Solution Approach 1:
The patent applies parameter changes by modifying the rigidity parameter of the conductor through forming treatment rather than changing the sheath formation process. The forming treatment creates different rigidity sections in the conductor itself, allowing the sheath to be applied uniformly over the entire conductor without requiring complex variable sheath formation processes
Data Source
AI summary
A wire harness includes a conducting path. The conducting path includes a conductor and a sheath. The conductor includes a first conductor and a second conductor which are connected to each other. The first conductor is disposed in a route regulation section requiring route regulation. The second conductor is disposed in another section than the route regulation section. The conductor in which the first conductor and the second conductor are connected to each other is covered with the sheath.