Wire Harness Ferrule Vibration Suppression
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Solution Overview
Problem
The wire harness experiences vibration issues due to a long distance between the terminal and the ferrule-swaged cable, affecting the durability, especially when subjected to continuous vibrations like those in vehicle applications.
Innovation Solution
A wire harness design featuring a ferrule with a swaging portion for the shield conductor and a tightening portion for the coating material, where the tightening portion is located closer to the terminal, along with a tubular metal ferrule that houses the central conductor and coating material, and a fixing member to secure the ferrule to the connector housing, effectively reducing vibration between the swaging position and the terminal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the distance between the terminal and the ferrule-swaged cable is long, then the cable assembly is easier to manufacture with standard ferrule positioning, but the central conductor and coating material oscillate under vibration, reducing durability
Solution Approach 1:
The ferrule is divided into two distinct functional portions: a swaging portion for securing the shield conductor and a tightening portion for securing the coating material. This segmentation allows each portion to perform its specific function optimally, with the tightening portion positioned closer to the terminal to prevent oscillation of the central conductor and coating material during vibration.
Solution Approach 2:
Different portions of the ferrule have different structural properties tailored to their specific functions. The swaging portion has a larger inner diameter suitable for the shield conductor, while the tightening portion has a smaller inner diameter suitable for the coating material. This local differentiation ensures optimal performance at each location along the ferrule.
2Reliability
If a single ferrule structure is used for both shield conductor and coating material, then the device complexity is reduced, but the coating material cannot be effectively tightened near the terminal, causing vibration issues
Solution Approach 1:
The ferrule is divided into two distinct functional portions: a swaging portion for securing the shield conductor and a tightening portion for securing the coating material. This segmentation allows each portion to perform its specific function optimally, with the tightening portion positioned closer to the terminal to prevent oscillation of the central conductor and coating material during vibration.
Solution Approach 2:
Instead of having the ferrule swage the shield conductor first and then rely on the sheath for coating material support, this invention inverts the approach by having the ferrule itself provide a tightening portion that directly secures the coating material near the terminal, reversing the traditional support hierarchy.
3Reliability
If the tightening portion is positioned farther from the terminal, then the ferrule structure is simpler, but the central conductor and coating material oscillate under vibration, affecting durability
Solution Approach 1:
Different portions of the ferrule have different structural properties tailored to their specific functions. The swaging portion has a larger inner diameter suitable for the shield conductor, while the tightening portion has a smaller inner diameter suitable for the coating material. This local differentiation ensures optimal performance at each location along the ferrule.
Solution Approach 2:
The tightening portion is positioned closer to the terminal to preliminarily secure the coating material and central conductor before they reach the terminal connection point. This preliminary securing action prevents oscillation and reduces stress on the terminal connection during subsequent vibration, improving overall durability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design effectively suppresses vibration of the central conductor and coating material, enhancing the durability of the wire harness by reducing oscillation and potential breakage or detachment at the terminal connection.
Implementation Method 1
the ferrule comprises a swaging portion for swaging the shield conductor
Implementation Method 2
a tightening portion for tightening the coating material
Implementation Method 3
a fixing member that fixes the ferrule to the connector housing
Data Source
AI summary
In order to provide a wire harness with which it is possible to suppress vibration of a coating material and a central conductor between a shield conductor swaging position and a terminal, this wire harness (1) is provided with: a first cable (21) that has a central conductor (201), a coating material (202) that coats the central conductor (201), and a shield conductor (203) that covers the coating material (202); a terminal (30) that is connected to the central conductor (201) of the cable (21); a connector housing (40) that houses an end of the first cable (21) along with the terminal (30); a first ferrule (51) that is electrically connected to the shield conductor (203) and has the central conductor (201) and the coating material (202) inserted thereinto; and a fixing member (61) that fixes the first ferrule (51) to the connector housing (40). The first ferrule (51) has a first swaging portion (511) for swaging the shield conductor (203) and a second swaging portion (512) for swaging the coating material (202), said second swaging portion (512) being positioned further to the terminal (30) side than the first swaging portion (511).