Wire Harness Exoskeleton Assembly for Flat-Pack Vehicle Installation
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Solution Overview
Problem
Commercial vehicles face logistical challenges in installing bulky and heavy wire harnesses due to their stiff coiled nature, which require heating and reworking to achieve the correct shape, leading to installation difficulties and lack of mechanical support.
Innovation Solution
A wire harness assembly is developed with an exoskeleton that stabilizes the shape of the harness, allowing it to be shipped flat-packed and easily installed without additional rework, comprising a frame structure with subframes and braces that couple to the vehicle's chassis, providing mechanical support and reducing the need for on-site manipulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If wire harnesses are shipped coiled to the place of final assembly, then they are compact for transport, but they become stiff and difficult to install requiring heating and rework
Solution Approach 1:
The wire harness is divided into multiple segments or sections, each capable of being routed independently through designated pathways. This segmentation allows the harness to be installed in a structured manner without requiring the entire harness to be manipulated as one stiff unit, thereby reducing installation difficulty while maintaining transport efficiency.
Solution Approach 2:
An intermediary routing structure or guide system is introduced between the wire harness and the vehicle chassis. This intermediary component facilitates the transition of the wire harness from a compact shipped state to an installed state by providing guided pathways that reduce the need for heating and manual rework during installation.
2Adaptability or versatility
If wire harnesses are made bulky to accommodate abundance of wires, then all wiring needs are met, but they become heavy and require periodic attachments
Solution Approach 1:
The wire harness routing system utilizes three-dimensional pathways and spatial optimization within the vehicle chassis. By routing wires through multiple dimensions and utilizing vertical and lateral spaces efficiently, the system accommodates abundant wiring connections without requiring excessive harness bulk, thereby reducing weight while maintaining full wiring capacity.
Solution Approach 2:
Different sections of the wire harness are optimized with varying levels of protection, bundling, and routing structures based on local requirements. High-stress or high-connection areas receive enhanced support and organization, while less critical areas use lighter configurations, reducing overall weight while maintaining adaptability for all wiring needs.
3Ease of operation
If wire harnesses are heated to provide necessary softness for installation, then installation becomes possible, but significant logistical challenges arise and mechanical support is compromised
Solution Approach 1:
The wire harness is pre-configured, pre-routed, and pre-secured to the vehicle chassis before final assembly. Routing pathways are prepared in advance, and the harness is positioned in its final configuration during manufacturing, eliminating the need for heating or on-site manipulation. This preliminary action ensures proper installation without adding logistical complexity.
Solution Approach 2:
The wire harness routing system is designed to be self-installing through snap-fit connections, friction-based securing, or self-locking mechanisms that automatically position and secure the harness as it is placed into the vehicle. This self-service approach eliminates the need for heating, external manipulation tools, or complex installation procedures while maintaining proper mechanical support.
Data Source
AI summary
Systems and techniques for a wire harness assembly that includes a wire harness subframe supporting a wire harness. The wire harness subframe stabilizes the shape of the wire harness and provides mechanical support. As the subframe stabilizes the shape of the wire harness, the wire harness assembly can be coupled to a vehicle without any additional rework steps.