Wire Harness Braided Shield Layout for Single-Fold Assembly
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Solution Overview
Problem
The assembly of wire harnesses is impaired due to interference from the braided wire during the attachment of a drawn-out portion to a connector, necessitating multiple folds and unfolding operations, which complicates the assembly process.
Innovation Solution
A wire harness design featuring a braided wire with specific portions configured to extend in opposite and aligned directions relative to the drawn-out portion, allowing for a single fold operation during assembly, along with a second tubular member to secure the braided wire, and shared metal materials to prevent galvanic corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the braided wire is folded back toward the outer circumference of the pipe during assembly, then the drawn-out portion can be attached to the connector housing, but the braided wire must be unfolded and refolded after assembly, increasing assembly complexity and reducing workability
Solution Approach 1:
The braided wire is pre-configured with a second portion that is drawn out in the opposite direction and folded back toward the outer circumference of the second tube before assembly. This preliminary configuration allows the drawn-out portion to be attached to the connector housing without requiring subsequent unfolding and refolding operations, thereby improving assembly workability and reducing process complexity
2Productivity
If the braided wire is configured to extend in opposite directions, then assembly is simplified to a single fold operation, but the structure becomes more complex
Solution Approach 1:
The braided wire is divided into three distinct portions: a first portion located between the outer circumferential surface of the first tube and an inner circumferential surface of the second tube, a second portion that is drawn out in the opposite direction and folded back, and a third portion that extends in the direction of the drawn-out portion. This segmentation enables the wire to be configured for single-fold assembly while maintaining structural organization and clarity
3Adaptability or versatility
If different metal materials are used for the pipe and braided wire, then design flexibility increases, but galvanic corrosion occurs reducing connection reliability
Solution Approach 1:
The pipe and braided wire are made from the same metal material to prevent galvanic corrosion. This material homogeneity ensures reliable electrical connections and long-term durability while still allowing design flexibility through appropriate material selection for the specific application requirements
Data Source
AI summary
A wire harness including: an electric wire; a first tube that is made of a metal and covers an outer circumference of the electric wire; a braided wire that is formed by braiding conductive strands into a tubular shape, is attached to an outer circumferential surface of the first tube, and covers an outer circumference of a drawn-out portion of the electric wire, the drawn-out portion being drawn out from an end of the first tube; and a second tube that is made of a metal and fixes the braided wire to the outer circumferential surface of the first tube.