Wire Harness Length Correction Using Cut-End Measurement Feedback
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Solution Overview
Problem
Conventional wire harness production results in surplus electric wire length being wasted, as it is designed to account for potential installation changes, leading to increased costs due to unnecessary material discard when such changes do not occur.
Innovation Solution
A wire harness electric wire length correcting device that includes an electric wire identifying means, measuring means, and correcting means, utilizing identification marks and mass measurement to adjust the electric wire length to a proper length, thereby reducing waste and optimizing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electric wire length is designed to be longer to account for potential installation changes, then the adaptability is improved, but the material waste increases when such changes do not occur
Solution Approach 1:
The patent applies preliminary action by pre-attaching identification marks to the electric wires during production, and pre-measuring the actual wire lengths after installation. This allows the system to have length correction data ready before the next production cycle, enabling precise length adjustment in subsequent operations without wasting material.
Solution Approach 2:
The patent implements feedback by measuring the actual electric wire lengths after installation and using this measured data to correct the design length values for future production. The correction information is stored and fed back into the production system, creating a closed-loop system that continuously improves material utilization based on actual usage patterns.
2Reliability
If the design value of electric wire length is configured to be longer, then the reliability of sufficient wire length is improved, but the production cost increases due to wasted material
Solution Approach 1:
The system measures actual wire lengths used in installation and feeds this information back to correct design values. This feedback loop ensures that future wire lengths are optimized to match actual needs, maintaining reliability while eliminating waste from overly conservative design estimates.
Solution Approach 2:
The patent changes the parameter of wire length design values based on measured actual usage. By dynamically adjusting this parameter from fixed overestimates to data-driven precise values, the system maintains sufficient length reliability while dramatically reducing material waste.
3Measurement precision
If identification marks are attached to electric wires for tracking, then the measurement accuracy is improved, but the device complexity increases
Solution Approach 1:
The patent uses identification marks as information copies that represent each electric wire's identity and measurement data. Instead of complex tracking systems, simple visual or scannable marks are used to carry wire identification information, enabling precise tracking and measurement without significant system complexity.
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 allows for precise adjustment of electric wire lengths, minimizing waste and reducing production costs by reusing the surplus wire length, enhancing installation efficiency and reducing material discard.
Implementation Method 1
measuring means for measuring a length of the cut off end of each electric wire
Data Source
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AI summary
A wire harness electric wire length correcting device, which corrects a design value of an electric wire length of an electric wire included in a wire harness, includes an electric wire identifying means including an identification mark, which is attached to an end portion of the electric wire, and which is to be cut off from the electric wire when the wire harness is installed on an installation target object, so as to use the identification mark to identify which electric wire an end cut off from the electric wire has been cut off from, a measuring means for measuring a length of the cut off end, and a correcting means for, for the electric wire identified by the electric wire identifying means, correcting the design value of the electric wire length of that electric wire, based on the length of the cut off end measured by the measuring means.