Wire Harness Routing Path Regulator Design
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Solution Overview
Problem
Conventional wire harness configurations require a large space for routing and are prone to misalignment due to twisting of routing path regulating members, leading to potential deviations from the predetermined path.
Innovation Solution
A wire harness design featuring a routing path regulator with higher rigidity than the core wire, adjacent to the core wire and covered by a second covering, which fixes the regulator to the core wire, suppressing relative displacement and eliminating the need for bending the regulator, core wire, and covering together, using a thermal shrinkable tube for easy coverage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a protector covering the outer circumference of the electrical wire is used to regulate the routing path, then the routing path is regulated, but the structure becomes large and requires more space
Solution Approach 1:
The invention extracts the routing path regulation function from a bulky protector and implements it through a thin routing path regulator placed only at the necessary location (between the electrical wire and heat shrinkable tube), eliminating the need for a large-scale protector while maintaining effective path control
Solution Approach 2:
The invention segments the protection and regulation functions: the heat shrinkable tube provides general protection and routing guidance, while the routing path regulator provides localized rigid support only where needed for path regulation, avoiding the need for a complete protective covering
2Ease of manufacture
If holding portions are provided at intervals along the routing path regulating member, then the electrical wire and regulator are held at each portion, but twisting occurs in the intervals causing misalignment
Solution Approach 1:
The invention changes the rigidity parameter of the routing path regulator by selecting a material with higher rigidity than both the electrical wire and heat shrinkable tube, which prevents twisting between holding portions and maintains precise alignment throughout the routing path
Solution Approach 2:
The invention creates a composite structure where the routing path regulator (made from rigid material like aluminum alloy) works together with the electrical wire and heat shrinkable tube, combining the rigidity of metal with the flexibility and protective properties of polymer materials to achieve both ease of assembly and precise alignment
3Strength
If the routing path regulator is made from a material different from the core wire, then the regulator can provide higher rigidity, but electrolytic corrosion may occur
Solution Approach 1:
The invention applies homogeneity by making the routing path regulator from the same material (copper alloy) as the core wire, ensuring material consistency throughout the electrical harness system and eliminating galvanic corrosion risks while maintaining the required rigidity through optimized cross-sectional dimensions
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 configuration allows for efficient path regulation with a simple setup, reducing structural size and preventing electrolytic corrosion by using a metal material for the regulator, making it easier to route the wire harness without bending difficulties and maintaining alignment.
Implementation Method 1
a second covering configured to cover an outer circumference of both the core wire and the routing path regulator
Data Source
AI summary
A wire harness including: an electrical wire including a core wire and a covering that covers an outer circumference of the core wire; and a routing path regulator that has a higher rigidity than the core wire and is configured to regulate a routing path of the electrical wire by being provided adjacent to the core wire between ends of the core wire and being covered, together with the core wire, by the covering.