Wire Harness Ring Binding for Fast, Stable Bundling
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Solution Overview
Problem
Existing wire harness manufacturing apparatuses face challenges in automating and speeding up the binding process of multiple wires while maintaining a consistent binding force, as filament-based bindings lack fixing mechanisms and are prone to shifting, leading to reduced binding efficiency.
Innovation Solution
A wire harness binding apparatus that uses a flexible wire rod to form a binding material by successively creating ring-shaped parts along the wire harness, coupling adjacent parts to maintain position and binding force, utilizing a wire rod supply unit and ring shape forming unit to automate the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a filament such as a thread or a string is used as a binding material to speed up the binding process, then the productivity is improved, but the binding force may be reduced due to lack of fixing mechanisms
Solution Approach 1:
The binding material is segmented into multiple ring-shaped parts along its length. Each ring-shaped part acts as an independent fixing mechanism that can elastically deform and snap back to maintain binding force, while the entire binding material remains continuous for automated application.
Solution Approach 2:
The binding material's physical parameters are changed by forming it into ring-shaped structures with specific elasticity characteristics. These ring-shaped parts can elastically deform during the binding process and then recover to maintain consistent binding force, transforming a simple continuous filament into a structured binding material with enhanced performance.
2Reliability
If adhesive tape is used to bind wires, then the binding force is maintained through fixing portions, but the productivity is reduced due to sequential winding and cutting operations
Solution Approach 1:
The binding material is designed as a continuous body with integrated ring-shaped parts, eliminating the need to stop, cut, and reposition separate binding elements. The continuous structure allows automated sequential application along the wire bundle, maintaining binding force through the elastic rings while enabling continuous high-speed operation.
3Productivity
If a continuous filament is wound helically around wires to speed up binding, then the productivity is improved, but the position may shift and helical shape may not be maintained
Solution Approach 1:
The continuous filament is segmented into multiple ring-shaped parts distributed along its length. Each ring-shaped part acts as a localized fixing point that maintains its position through elastic deformation, preventing the binding material from shifting while allowing continuous automated application.
Solution Approach 2:
The binding material is formed into ring-shaped (curved) structures rather than straight segments. These ring-shaped parts can elastically deform and conform to the wire bundle shape, maintaining positional stability and the overall helical binding pattern during automated application.
Data Source
AI summary
Provided is a wire harness binding apparatus that is capable of automating and speeding up the work of binding a plurality of wires with a binding material by successively binding the wires with the binding material, and that forms a wire harness capable of suppressing a decrease in the binding force that binds the wires. The apparatus includes a wire rod supply unit for supplying a wire rod near an object to be bound, and a ring shape forming unit for forming a ring-shaped part by curving a portion of the wire rod supplied from the wire rod supply unit. The ring shape forming unit successively forms a plurality of ring-shaped parts with the wire rod supplied from the wire rod supply unit, arranges the plurality of ring-shaped parts along the longitudinal direction of the object to be bound, and forms a binding material by connecting adjacent ring-shaped parts along the longitudinal direction of the object to be bound.