Wire Harness Roll Prevention Asymmetric Collar
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Solution Overview
Problem
High voltage wire harnesses with metal pipes face issues of edge damage to electric wires, rolling during insertion, and dimensional variations due to twisting, which affect workability and quality, and incur additional costs for prevention measures.
Innovation Solution
A wire harness design featuring electrically conductive paths aligned in a predetermined direction with a shaped pullout hole and a roll prevention portion in a planar or protruding shape to maintain alignment and prevent rolling, ensuring stable orientation and position of the tubular body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a circular metal pipe is used, then manufacturing is simplified, but the pipe easily rolls during wire insertion affecting workability
Solution Approach 1:
The protective collar is designed with an asymmetric feature such as a flat spot, protrusion, or non-circular cross-section that prevents the assembly from rolling. This asymmetric element breaks the rotational symmetry of the circular pipe, providing stable positioning during wire insertion while maintaining the simplicity of the circular pipe's manufacturing.
2Ease of operation
If the metal pipe is inhibited from rolling by using a jig, then workability is improved, but time is consumed by attaching and detaching the jig
Solution Approach 1:
The protective collar with its asymmetric feature provides self-positioning and self-stabilizing functionality. The collar's design inherently prevents rolling and maintains proper orientation during wire insertion without requiring external jigs or fixtures, eliminating the time-consuming attachment and detachment operations.
Solution Approach 2:
The anti-rolling feature is built into the protective collar that is pre-installed on the pipe. This preliminary incorporation of the positioning function eliminates the need for separate jig-based positioning during the wire insertion process, reducing operational time and complexity.
3Ease of operation
If additional work is performed on the metal pipe without using a jig, then cost increases, but workability may be improved
Solution Approach 1:
The protective collar combines multiple functions into a single component: it protects wire sheathes from edge damage, prevents the pipe from rolling, and maintains proper orientation during insertion. By merging these functions into one integrated part, the need for multiple separate operations or components is eliminated, avoiding additional manufacturing complexity and cost.
Data Source
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AI summary
A wire harness (9) comprises one or a plurality of electrically conductive paths (15), a tubular body (16) into which the one or plurality of electrically conductive paths (15) are to be inserted, and a protector (18) to be engaged with a terminal (17) of the tubular body (16), wherein the protector (18) has a terminal engagement section (20) to be engaged with the terminal (17) of the tubular body (16), and a roll prevention portion (32) which serves as an area that is mounted on a predetermined mounting surface without rolling, is formed in the terminal engagement section (20).