Wire Harness Route Regulator Elastic Deformation
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Solution Overview
Problem
Conventional wire harnesses require remaking of the mold for the protector when the wire diameter changes, leading to increased costs due to the need for specific dimensions in the protector's design.
Innovation Solution
A wire harness with a flexible outer cover and a route regulator that includes an elastic deformation portion, allowing for easy adjustment of the wire route and accommodating different wire diameters using a single type of route regulator, which is elastically deformable and can be fixed to the outer cover using a fixing member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin molded protector is used with specific dimensions to regulate wire route, then the wire route can be effectively regulated, but the mold must be remade when wire diameter changes, increasing costs
Solution Approach 1:
The route regulator is designed with an elastic deformation portion that allows it to change its dimensional parameters (cross-sectional size) elastically. This enables the same regulator to accommodate different wire diameters by deforming to match the outer cover's diameter, eliminating the need for multiple fixed-dimension molds and reducing manufacturing costs while maintaining effective wire route regulation
Solution Approach 2:
The route regulator transitions from a static, fixed-dimension component to a dynamic, adaptable component through the elastic deformation portion. This dynamic characteristic allows the regulator to adjust its shape and size in response to different outer cover diameters, providing versatility across multiple specifications without requiring separate molded parts for each size
2Ease of manufacture
If a fixed-dimension protector is designed for a specific wire diameter, then the manufacturing cost for that specification is optimized, but the design cannot accommodate changes in wire specification
Solution Approach 1:
The route regulator is designed as a universal component that can serve multiple wire diameter specifications. The elastic deformation portion enables a single regulator design to function with outer covers of varying diameters, making one component multi-functional across different wire specifications and eliminating the need for separate regulators for each size
3Manufacturing precision
If the route regulator is made rigid to maintain shape, then the wire route regulation is precise, but it cannot adapt to different outer cover diameters
Solution Approach 1:
The route regulator employs a composite structure where different portions have different mechanical properties. The elastic deformation portion provides flexibility for adapting to different diameters, while other portions maintain sufficient rigidity to ensure precise wire route regulation. This local differentiation of mechanical properties allows the component to simultaneously achieve adaptability and precision
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
Enables easy handling of changes in specifications by allowing the route regulator to adjust its size to fit various outer cover diameters, maintaining the desired shape of the flexible outer cover and reducing production costs.
Implementation Method 1
the route regulator includes an elastic deformation portion that is elastically deformable
Data Source
AI summary
A wire harness including: a wire; a flexible outer cover covering the wire; a route regulator that has an axial direction extending along a route where the wire is routed, and that is configured to regulate the route where the wire is routed, from an outside of the outer cover; and a fixing member that is configured to fix the route regulator to the outer cover, wherein the route regulator includes an elastic deformation portion that is elastically deformable.