Wire Harness Mold Standardization via Variable Conductor Thickness
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Solution Overview
Problem
The complexity in manufacturing wire harnesses for vehicles arises from the need to accommodate high-voltage and low-voltage wires with different diameters, requiring multiple metal molds and complicating the bending process, especially when routing under vehicle floors.
Innovation Solution
The use of tubular shape-retaining conductive members with varying thicknesses allows for standardized molds and simplified manufacturing by ensuring the outer diameters of these members remain within a certain range, enabling equal outer diameters for low-voltage tubular members and standardized holding portions, which simplifies the bending and assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple metal molds are prepared to accommodate different diameters of high-voltage and low-voltage wires, then the manufacturing precision can be maintained, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent changes the parameter of the holding portion's outer diameter to match the standard pipe bender mold diameter. By making the holding portion's outer diameter equal to the mold diameter, the same mold can be used for both high-voltage and low-voltage wires, eliminating the need for multiple specialized molds while maintaining manufacturing precision
Solution Approach 2:
The holding portion is designed with a universal outer diameter that allows it to be processed using the same standard pipe bender mold regardless of the wire type. This multi-functional design enables a single mold to serve multiple purposes for different wire diameters, reducing device complexity
2Stability of the object's composition
If rigid electrically conductive members are used instead of flexible wires to prevent hanging down, then the structural stability improves, but the manufacturing complexity increases due to different bending requirements
Solution Approach 1:
The patent changes the outer diameter parameter of the holding portion to match the standard mold diameter. This parameter adjustment allows rigid conductive members to be bent using standard equipment, simplifying the bending process while maintaining the anti-hanging structural stability
Solution Approach 2:
The holding portion is designed with specific local properties (outer diameter matching mold size) that enable it to be processed by standard equipment. This localized design feature allows the rigid conductive member to maintain stability while being compatible with standard bending processes
3Ease of manufacture
If the outer diameters of holding portions are standardized to match pipe bender molds, then the ease of manufacture improves, but the adaptability to different wire sizes may be reduced
Solution Approach 1:
The patent segments the wire harness structure into a holding portion and the actual wire conductor. The holding portion is standardized for manufacturing purposes, while the wire conductor inside can vary in diameter. This segmentation allows standardization of the outer structure while maintaining adaptability of the inner conductor
Solution Approach 2:
The holding portion acts as an intermediary between the standard pipe bender mold and the various wire sizes. By standardizing the holding portion's outer diameter to match the mold, it serves as a mediator that allows different wire sizes to be processed using the same standard equipment
Data Source
AI summary
A wire harness, including: a plurality of tubes that each include a tubular shape-retaining conductor having a conductive property and a shape-retaining property, the plurality of tubes being routed in parallel, wherein: a conductive tube, that includes an insulating cover that covers the shape-retaining conductor, is included among the plurality of tubes, and thicknesses of the shape-retaining conductors that are included in at least two tubes among the plurality of tubes are different to each other.