Wire Harness Assembly With Release Layers for Complex Routing

Solution Overview

Problem

Conventional wire harness manufacturing processes are costly and labor-intensive, especially when routing paths for electric wires are complex or branched, as they require manual assembly of exterior members.

Innovation Solution

A method involving a harness assembling process with a mold release member to prevent sticking, and a joining process that automates the assembly of mesh-like and sheet-like exterior members around electric wires using ultrasonic welding or other techniques, eliminating the need for manual winding or insertion into corrugated tubes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual assembly of exterior members is used for complex routing paths, then assembly quality is secured, but manufacturing cost increases and productivity decreases

Engineering Contradiction:

Improveassembly qualityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual mechanical assembly operations with an automated joining system that uses ultrasonic welding or adhesive application mechanisms. The joining device automatically positions and attaches exterior members to electric wires along complex routing paths, eliminating the need for manual winding and attachment while maintaining consistent assembly quality through controlled processing parameters.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a self-positioning mechanism where the joining device automatically follows the routing path and positions exterior members without manual intervention. The system uses guides and positioning fixtures to ensure precise placement of exterior members on electric wires, enabling the assembly process to serve itself without continuous human operation.

Inventive Principle:

Principle #25Self-service

2Manufacturing precision

If manual assembly of exterior members is used for branched electric wires, then assembly quality is secured, but labor cost increases

Engineering Contradiction:

Improveassembly qualityVSAvoidlabor cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces manual mechanical assembly operations with an automated joining system that uses ultrasonic welding or adhesive application mechanisms. The joining device automatically positions and attaches exterior members to electric wires along complex routing paths, eliminating the need for manual winding and attachment while maintaining consistent assembly quality through controlled processing parameters.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements a self-positioning mechanism where the joining device automatically follows the routing path and positions exterior members without manual intervention. The system uses guides and positioning fixtures to ensure precise placement of exterior members on electric wires, enabling the assembly process to serve itself without continuous human operation.

Inventive Principle:

Principle #25Self-service

3Productivity

If multiple wire harnesses are assembled simultaneously, then productivity increases, but wire harnesses stick to each other

Engineering Contradiction:

Improveproduction volumeVSAvoidseparation between harnesses

Core Design Contradiction:

ProductivityVSStability of the object's composition

Solution Approach 1:

The patent introduces a mold release member as an intermediary substance placed between adjacent wire harnesses during simultaneous assembly. This mold release member prevents direct contact and adhesion between the exterior members of neighboring harnesses, allowing multiple harnesses to be assembled in parallel without sticking together while maintaining production efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This method reduces manufacturing costs and automates the assembly process, allowing for efficient production of wire harnesses with complex routing paths without manual labor.

Implementation Method 1

placing a mold release member capable of preventing the wire harnesses adjacent to each other from sticking to each other

Methodology Applied

Scientific EffectNon-stick surface property: Lubrication

Implementation Method 2

a joining process of joining components of the wire harness to each other for each wire harness

Methodology Applied

Scientific EffectUltrasonic welding: Ultrasonic Vibration

Data Source

PatentUS20240347232A1Method for manufacturing wire harness

Publication Date: 2024.10.17 YAZAKI CORP

AI summary

A method for manufacturing a wire harness includes a harness assembling process, a mold release member installing process of, when a plurality of wire harnesses are assembled, each time the harness assembling process is ended, placing a mold release member on a wire harness, and a joining process of joining components of the wire harness together for each wire harness. The harness assembling process includes a first outer layer installing process of installing an exterior member as one outer layer on a jig plate, an inner layer installing process of routing a protection target part of at least one routed electric wire to the exterior member as the one outer layer, and a second outer layer installing process of overlaying an exterior member as another outer layer on the protection target part and the exterior member.