Wire Harness Fixing Member Suppresses Sheet Material Separation
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Solution Overview
Problem
Existing methods for fixing electrical wires and sheet-like exterior members in a wire harness to a vehicle using direct welding can lead to separation when subjected to bending or pulling forces, as the end portion of the sheet material is fixed, causing the electrical wire and sheet material to disconnect.
Innovation Solution
A fixing member-attached wire harness design that includes a welding region where the electrical wire and sheet material are welded, with a terminal side region that has a first region following bending and a second region linked to the opposite side, supported by a fixing member to prevent separation, and additional features such as spot welding parts or a perforated line to enhance stability and ease of evaluation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the insulating covering of the electrical wire and the sheet material are directly welded and fixed, then the manufacturing process is simplified and production efficiency is improved, but the electrical wire and sheet material may separate when bending or pulling forces are applied
Solution Approach 1:
The sheet material is divided into multiple regions: a first region that follows bending of the terminal side, a second region that is prevented from following bending by the fixing member support, and an intermediate region connecting them. This segmentation allows different parts of the sheet material to respond differently to bending forces, preventing separation while maintaining the direct welding approach.
Solution Approach 2:
Different regions of the sheet material are given different functional properties: the first region is designed to be flexible and follow bending, the second region is supported to remain stable, and the intermediate region transitions between them. This local differentiation of mechanical properties allows the structure to accommodate bending forces without causing separation at the welded connection.
2Reliability
If the end portion of the sheet material is fixed to prevent separation, then connection reliability is improved, but the structure becomes rigid and cannot accommodate bending forces
Solution Approach 1:
The sheet material is segmented into regions with different support characteristics. The first region near the terminal side is allowed to bend freely, while the second region is supported by the fixing member. This segmentation creates a gradient of rigidity that maintains both flexibility where needed and stability where required.
Solution Approach 2:
The structure transitions from a static, uniformly rigid configuration to a dynamic system where different regions have different degrees of freedom. The first region dynamically follows bending forces, while the second region remains relatively stable due to fixing member support, allowing the structure to adapt to varying mechanical loads.
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
The design effectively suppresses separation of the electrical wire and sheet material during bending or pulling, ensuring the wire harness remains securely attached to the vehicle, with improved quality evaluation and reduced welding time.
Implementation Method 1
a method of directly fixing an insulating covering of the electrical wires and a sheet material by welding
Data Source
AI summary
A fixing member-attached wire harness includes a wire harness having an electrical wire and a sheet material welded to an insulating covering of the electrical wire and a fixing member attached to the wire harness for fixing the wire harness to a vehicle. When bending force is applied to a terminal side region part of the wire harness in a state where the fixing member is fixed to a fixed object a welding region part of the wire harness includes a first region part following a bending of the terminal side region part and a second region part linked to an opposite side of the first region part from the terminal side region part and prevented from following the bending of the terminal side region part by support force of the fixing member.