Wire Harness Layout Using Equal-Length Wires Across Uneven Terminals
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Solution Overview
Problem
Existing wire harness designs require multiple types of electric wires with different lengths due to varying intervals between terminals, increasing the number of component types.
Innovation Solution
A wire harness design where the first and second terminals are arranged at different orthogonal intervals, with electric wires having the same length, and connection portions positioned to maintain uniformity, allowing for identical terminals and wires to be used, and incorporating elongated holes for flexible terminal alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If electric wires are designed with different lengths to match varying terminal intervals, then connection accuracy is improved, but the number of component types increases
Solution Approach 1:
The patent changes the spatial arrangement parameters of connection portions rather than wire lengths. By varying the positions of first and second connection portions along the wire length, the patent achieves different effective connection distances while using wires of uniform length, thus resolving the contradiction between connection accuracy and component variety.
Solution Approach 2:
The patent introduces positional variation in the orthogonal direction (second direction) as an additional degree of freedom. Instead of varying wire lengths (one-dimensional solution), the patent varies the positions of connection portions in both the first direction (wire length direction) and second direction (orthogonal direction), effectively using two-dimensional positioning to solve a one-dimensional connection accuracy problem.
2Manufacturing precision
If multiple types of electric wires are prepared to accommodate different terminal distances, then connection precision is improved, but inventory complexity and assembly time increase
Solution Approach 1:
The patent makes a single wire type serve multiple functions by varying the positions of connection portions. The same wire design can accommodate different terminal intervals simply by repositioning the connection portions, eliminating the need for multiple wire types and simplifying inventory management while maintaining connection precision.
Solution Approach 2:
The patent changes the positional parameters of connection portions rather than the wire length parameter. This allows a single wire type to be adapted to different connection scenarios by adjusting where connections are made along the wire, thereby improving assembly efficiency while maintaining precision.
3Adaptability or versatility
If connection portions are positioned at varying distances from terminals, then flexibility in accommodating different terminal arrangements is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the wire into distinct functional zones: first connection portions near first terminals and second connection portions near second terminals. By independently positioning these segments in the orthogonal direction, the patent achieves flexibility in accommodating different terminal arrangements while keeping the overall wire structure simple and manufacturable.
Solution Approach 2:
The patent uses the orthogonal direction (second direction) as an additional positioning dimension to achieve flexibility. By allowing connection portions to be positioned at different locations in both the first and second directions, the patent accommodates various terminal arrangements without complicating the wire manufacturing process.
Data Source
AI summary
First terminals according to an embodiment of the present disclosure are arranged at a first interval in a second direction, and second terminals are arranged at a second interval in the second direction. The first interval differs from the second interval. The electric wires have the same length. The electric wires include first connection portions, respectively connected to the first terminals, and second connection portions, respectively connected to the second terminals. The second connection portions are arranged next to each other in the second direction, and ones of the first connection portions having a longer interval from ones of the corresponding second connection portions in the second direction are arranged at positions closer to the corresponding second connection portions in the first direction.