Wire Harness Holding Member for 3D Shape Accuracy
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Solution Overview
Problem
Existing wire harness assembly methods for vehicles often result in twisting issues during the transition from two-dimensional layouts to three-dimensional configurations, requiring complex calculations and potentially leading to suboptimal wire lengths and increased operational complexity.
Innovation Solution
A wire harness design featuring three or more branch line portions with connectors, where the holding member positions connectors orthogonally to each other, and branch line grouping parts with magnets allow for easy alignment and binding, mimicking the in-vehicle configuration, reducing twisting and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the wire harness is assembled using conventional two-dimensional layout methods, then the assembly process is simple, but twisting occurs during transition to three-dimensional shape
Solution Approach 1:
The patent applies preliminary action by pre-positioning connectors and branch lines in their final three-dimensional configurations using holding members before the actual assembly process. The holding members maintain predetermined positional relationships, allowing the wire harness to be assembled in its final 3D shape without subsequent twisting adjustments.
Solution Approach 2:
The holding member acts as an intermediary device that temporarily maintains the three-dimensional spatial relationships between connectors and branch lines during assembly. This intermediary structure enables accurate 3D positioning without requiring complex direct measurement and adjustment procedures.
2Manufacturing precision
If complex calculations are performed to minimize twisting, then twisting is reduced, but the design process becomes complex
Solution Approach 1:
The patent replaces complex mechanical calculation and adjustment systems with a simplified holding member system. Instead of calculating expected twisting amounts and making iterative adjustments, the holding member physically constrains the wire harness components in their correct three-dimensional positions, eliminating the need for complex design calculations.
3Shape
If the wire harness is arranged in three-dimensional configuration, then it matches in-vehicle arrangement, but twisting occurs during assembly
Solution Approach 1:
The holding members are designed to pre-establish the three-dimensional configuration with accurate positional relationships between connectors and branch lines. By maintaining these predetermined positions during assembly, the wire harness achieves its final 3D shape without twisting or subsequent adjustments.
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 solution effectively minimizes twisting and maintains a shape closer to the in-vehicle configuration, reducing the need for complex calculations and operational adjustments, while also reducing weight and allowing for easier maintenance and production processes.
Implementation Method 1
the branch line grouping parts include magnets, and the branch line grouping parts can be joined to each other using the magnets
Data Source
AI summary
In order to provide a technique for obtaining a wire harness with a shape closer to that when arranged in a vehicle, a wire harness in which three or more branch line portions branch from a trunk line portion and end portions of the branch line portions are respectively provided with connectors, includes: a holding member that holds the branch line portions such that a connector is positioned away from one of the three or more connectors in a first direction that is orthogonal to a terminal insertion direction and a connector is positioned away from that one connector in a second direction that is orthogonal to the first direction, when the trunk line portion is held such that the connectors are suspended.