Wire Harness Crimping Member Arcuate Design
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Solution Overview
Problem
Existing high-voltage wire harness designs risk damaging braided shielding members due to strong crimping forces, which can lead to cutting when tensile forces are applied.
Innovation Solution
A wire harness configuration featuring a tubular shielding member, a braided shielding member, and a crimping member with a bent portion and extending portion, where the bent portion has a substantially arcuate cross-section without edges and the extending portion is larger in diameter, preventing direct contact and damage during crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the crimp ring is fixedly connected to the braided member with a strong force during crimping, then the connection strength between the tubular shielding member and braided shielding member is improved, but the braided shielding member may be damaged by the edge of the open end of the crimp ring
Solution Approach 1:
The open end of the crimp ring is bent to form a substantially arcuate cross-section, eliminating sharp edges that could damage the braided shielding member. This curved configuration maintains the strong connection force while preventing mechanical damage to the braided structure during and after crimping.
Solution Approach 2:
The bent portion is formed in advance to prevent the harmful effect of edge contact before it occurs. By pre-bending the open end to an arcuate shape, the design anticipates and prevents the potential damage that would otherwise occur during the crimping process or when tensile forces are applied.
2Ease of manufacture
If the open end of the crimp ring is left straight, then the manufacturing process is simpler, but the edge of the open end can bite into and damage the braided member under tensile force
Solution Approach 1:
The open end is bent to form a substantially arcuate cross-section, which prevents the edge from biting into the braided member under tensile load. This simple bending operation adds minimal complexity to manufacturing while dramatically improving the reliability and preventing damage to the braided shielding member.
Data Source
AI summary
A wire harness includes one or more electrically-conducting paths, a tubular shielding member configured to collectively accommodate the electrically-conducting paths, a braided shielding member including a cylindrical braided member and connected to an end of the tubular shielding member, and an annular crimping member including a fixing portion which fixedly connects the braided shielding member and the tubular shielding member by crimping, and a bent portion which is formed by bending an open end of the fixing portion to outside of the fixing portion.