Wire Harness Insulation Reliability in Bent Pipes
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Solution Overview
Problem
Conventional wire harnesses in vehicles experience a decrease in insulation reliability due to compression of electric wires within metal pipes during bending, leading to reduced thickness of insulating coatings.
Innovation Solution
A wire harness configuration featuring first and second electric wire members, a tubular member, and fixing members, where the second electric wire member is arranged to avoid compression by being spaced apart from the outer and inner surfaces of the first electric wire members and the tubular member, maintaining insulation reliability through strategic positioning and sizing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple electric wires are simultaneously bent inside a metal pipe during the bending process, then the wire harness can be assembled efficiently, but the electric wires come into contact with the inner circumferential surface and overlap, causing compression that reduces insulation reliability
Solution Approach 1:
The patent applies preliminary action by pre-arranging the spatial positions of multiple electric wires before the bending process. The wires are positioned such that their centers are located at different distances from the center of the metal pipe, and their projection positions on the cross-sectional plane are predetermined. This pre-arrangement ensures that during bending, wires do not overlap or come into contact with the inner circumferential surface, preventing compression of insulating coatings and maintaining insulation reliability while allowing simultaneous bending of multiple wires.
2Volume of moving object
If electric wires are arranged closely inside the metal pipe to maximize space utilization, then the pipe diameter can be reduced, but the wires are compressed between the inner surface and outer circumferential surfaces, reducing insulating coating thickness
Solution Approach 1:
The patent applies local quality by creating non-uniform spatial distribution of electric wires within the metal pipe. Specifically, wires are positioned at different radial distances from the pipe center, with some wires closer to the center and others farther away. This localized variation in wire positioning ensures that each wire has sufficient clearance from the inner circumferential surface during bending, preventing compression of insulating coatings while still achieving compact overall arrangement and optimized pipe diameter.
Data Source
AI summary
A wire harness including a plurality of first electric wire members that each have a first flexible electric wire and a hard electric wire electrically connected to the first flexible electric wire: a second electric wire member that is a second flexible electric wire: a tube through which the plurality of first electric wire members and the second electric wire member pass: and a fixing member for bundling the plurality of first electric wire members and the second electric wire member, wherein: the tube includes a bend, and the wire harness is configured to achieve a first arrangement.