Wire Harness Holder Structure for Stable Wire Routing
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Solution Overview
Problem
Conventional wire harnesses for vehicles, such as hybrid and electric vehicles, face issues with electric wires deviating from their intended positions within the shield pipe, leading to compromised routing and potential damage to insulation coatings.
Innovation Solution
A wire harness configuration that includes a tubular member with attached holders at both ends, featuring housing recesses to securely position and maintain the electric wire members, reducing the likelihood of displacement and wear on insulation coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plastic holder is attached to the shield pipe to prevent contact between the shield pipe edge and electric wires, then the insulation coatings of the electric wires are protected from damage, but the electric wires may turn or move within the holder causing deviation from intended positions
Solution Approach 1:
The holder is designed with localized contact structures including contact portions that engage with specific regions of the electric wires and positioning protrusions that fit into corresponding recesses. This localized engagement ensures wires remain secured at critical points while maintaining overall flexibility for routing operations.
Solution Approach 2:
The holder incorporates pre-formed positioning protrusions and contact portions that are designed to automatically guide and secure electric wires into their intended positions during installation. This preliminary structuring prevents wire deviation before it occurs, eliminating the need for post-installation adjustments.
2Ease of manufacture
If the holder structure is simplified to improve ease of installation, then the manufacturing process becomes less complex, but the holder cannot effectively prevent wire movement and position deviation
Solution Approach 1:
The holder is designed as a unitary molded piece with integrated positioning features rather than requiring multiple separate components. The positioning protrusions, contact portions, and wire receiving spaces are all formed in a single molding process, achieving complex wire positioning functionality without increasing manufacturing steps or assembly complexity.
Solution Approach 2:
The holder utilizes elastomeric material properties with specific hardness and elasticity parameters that enable the contact portions to flexibly engage with wires of varying diameters while maintaining secure positioning. The material parameters are selected to provide sufficient friction for wire retention while allowing easy insertion during installation.
Data Source
AI summary
A wire harness includes a first electric wire member including a first flexible wire and a hard wire electrically connected to the first flexible wire, a second electric wire member including a second flexible wire, and a tubular member through which the first and second electric wire members extend. The wire harness also includes a tubular holder that is attached to a longitudinal end portion of the tubular member and holds the first and second electric wire members therein. The holder has a first housing recess that is located in an inner surface of the holder and houses the second electric wire member.