Wire Harness Intermediate Member Segmentation
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Solution Overview
Problem
High-voltage wire harnesses used in hybrid and electric vehicles require lengthy fabrication, leading to poor productivity due to the need for continuous extension during assembly.
Innovation Solution
A wire harness intermediate member is introduced, comprising intermediate conducting paths, routing path retaining means, and protection/shielding means, which can be fabricated separately from terminal members, allowing for assembly in shorter lengths and improved handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the wire harness is fabricated as a single continuous piece, then the electrical connection is complete, but the fabrication time and processing complexity increase significantly
Solution Approach 1:
The wire harness is divided into multiple separate components: terminal members and an intermediate member. Each component can be fabricated independently and then assembled together, reducing overall fabrication time and complexity while maintaining complete electrical connectivity.
Solution Approach 2:
The terminal members and intermediate member are fabricated separately in advance before final assembly. This preliminary fabrication of separate components allows for parallel processing and reduces the overall production cycle time.
2Ease of operation
If the wire harness is made in shorter sections, then handling and fabrication ease improve, but the number of connection points and assembly steps increase
Solution Approach 1:
The wire harness is segmented into manageable terminal members and an intermediate member, improving handling ease during fabrication and installation while maintaining a relatively simple assembly structure through standardized connection interfaces.
Data Source
AI summary
An intermediate member that enables enhancement of ease of fabrication of a wire harness and a wire harness including such an intermediate member are provided. A wire harness is divided into an intermediate member placed in an intermediate portion of the wire harness and two terminal members placed at respective terminals of the wire harness and to be connected to equipment. After being separately fabricated, the intermediate member and the two terminal members are connected together, whereupon fabrication of the wire harness is completed. The intermediate member includes one or a plurality of intermediate conducting paths, intermediate routing path retaining means retaining a cable routing path geometry of the intermediate conducting paths; intermediate shield means covering and shielding the intermediate conducting paths; and intermediate protection means covering and protecting the intermediate conducting paths.