Wire Harness Extra-Length Storage for Easier Connector Mating
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Solution Overview
Problem
The connection of connectors in wire harnesses can be difficult due to the positional relationship between the electric wire fixing portion in the protector and the mating connector, especially when the distance is short.
Innovation Solution
A wire harness design that includes a first and second lead-out port, an electric wire fixing portion, a main storage, and an extra length storage with a pillar, where the electric wire is wound around the pillar in the extra length storage to absorb slack, increasing the range of movement and preventing sharp bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the distance from the electric wire fixing portion to the mating connector is short, then the wire harness structure is compact, but the connector connection workability deteriorates
Solution Approach 1:
The protector is divided into multiple functional regions: a main storage portion for regular wire storage and an extra length storage portion specifically designed to store additional wire length. This segmentation allows the wire harness to maintain a compact overall structure while providing accessible extra wire length at the connector end, improving connection workability without increasing the total volume significantly.
Solution Approach 2:
The extra length of electric wire is pre-stored in the extra length storage portion of the protector before connection is needed. This preliminary preparation ensures that when connector connection is required, sufficient wire length is already available, eliminating the need to pull or extend the wire during the connection operation itself.
2Stability of the object's composition
If the electric wire is fixed tightly to the protector, then the wire positioning is stable, but the connector movement freedom deteriorates
Solution Approach 1:
The wire management system is segmented into two zones: a fixed portion where the electric wire is securely anchored to the protector for stability, and a movable portion in the extra length storage where the wire can be freely pulled out. This segmentation maintains positioning stability at the fixed point while providing movement freedom at the connector end.
Solution Approach 2:
The wire constraint parameter changes along its length: tightly constrained at the fixing portion for stability, and progressively more free in the extra length storage portion. This gradient change in constraint parameters allows the wire to maintain stable positioning while still enabling sufficient movement freedom for connector operation.
Data Source
AI summary
A wire harness that includes: an electric wire; a protector that stores part of the electric wire in a length direction; and a connector provided at one end of the electric wire led out from the protector, wherein the protector includes: a first lead-out port and a second lead-out port from each of which the electric wire is led out; an electric wire fixing portion to which the electric wire is fixed; a main storage that is provided between the electric wire fixing portion and the first lead-out port and that stores the electric wire; and an extra length storage that is provided between the electric wire fixing portion and the second lead-out port and that is capable of storing an extra length of the electric wire.