Wire Harness Lock Member Assembly for Curved Protector Routing

Solution Overview

Problem

The assembly process of wire harnesses is complicated due to direct fixation of electric wires to protectors via band members, which complicates the assembly work and reduces productivity, especially when dealing with three-dimensionally curved protectors.

Innovation Solution

A wire harness design that includes a lock member with a band insertion portion and locking portion, allowing the electric wire to be fixed to a protector by attaching a lock member to the electric wire, simplifying the fixing process and promoting automation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the electric wire is directly fixed to the protector via the band member, then the fixing is simple, but the assembly work becomes complicated and productivity decreases

Engineering Contradiction:

Improvefixing simplicityVSAvoidassembly productivity

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The fixing system is divided into separate functional components: the band member for attachment to the electric wire, the lock member with locking portion for securing, and the protector with locked portion. This segmentation allows each component to be optimized independently and assembled in a standardized sequence, improving both ease of manufacture and productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lock member acts as an intermediary component between the band member and the protector. It provides a standardized locking interface that simplifies the assembly process by eliminating the need for complex positioning and holding operations, thereby resolving the contradiction between simple fixing and high productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If the electric wire is directly fixed to the protector via the band member, then fewer components are needed, but the assembly process requires multiple jig placements and becomes complicated

Engineering Contradiction:

Improvenumber of componentsVSAvoidassembly operation simplicity

Core Design Contradiction:

Device complexityVSEase of operation

Solution Approach 1:

The fixing system is divided into separate functional components: the band member for attachment to the electric wire, the lock member with locking portion for securing, and the protector with locked portion. This segmentation allows each component to be optimized independently and assembled in a standardized sequence, improving both ease of manufacture and productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The introduction of the lock member changes the operational parameters of the assembly process from requiring precise positioning and multiple jig placements to a simple locking operation. This parameter change transforms a complex multi-step process into a straightforward single-step operation, resolving the contradiction between component count and operational simplicity.

Inventive Principle:

Principle #35Parameter changes

3Device complexity

If the electric wire is directly fixed to the protector via the band member, then the structure is simple, but automation of wire harness manufacturing is difficult

Engineering Contradiction:

Improvestructural simplicityVSAvoidmanufacturing automation

Core Design Contradiction:

Device complexityVSExtent of automation

Solution Approach 1:

The fixing system is divided into separate functional components: the band member for attachment to the electric wire, the lock member with locking portion for securing, and the protector with locked portion. This segmentation allows each component to be optimized independently and assembled in a standardized sequence, improving both ease of manufacture and productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lock member is designed to be automatically attachable to the protector through a simple locking motion without requiring external positioning devices or complex alignment procedures. This self-service capability enables automated assembly systems to perform the fixing operation efficiently, resolving the contradiction between structural simplicity and automatability.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS20250316405A1Wire Harness and Wire Harness Manufacturing Method

Publication Date: 2025.10.09 YAZAKI CORP

AI summary

A wire harness includes an electric wire, a protector that includes a locked portion and protects the electric wire, and a lock member that includes a band insertion portion through which a band member is inserted and a locking portion locked to the locked portion, and that is fixed to the electric wire via the band member by winding the band member inserted through the band insertion portion around the electric wire. The electric wire is fixed to the protector by locking the locking portion of the lock member fixed to the electric wire to the locked portion of the protector.