Wire Harness Transport Connector for Tangle-Free Cable Handling
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Solution Overview
Problem
The existing methods for producing wiring harnesses often result in tangled cables due to the manual handling and bundling process, which complicates the mechanical connection and transportation of electrical cables.
Innovation Solution
A transport connector with a design featuring a first and second receptacle, clamping sections, and a separating web that allows for easy insertion and secure clamping of electrical cables, preventing tangling and facilitating automated handling and rolling of cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If cables are laid individually on a preform board and wrapped in a bundle, then a wiring harness can be formed, but the cables become tangled and knotted
Solution Approach 1:
The transport connector serves as an intermediary device that temporarily holds multiple cables in a structured manner during manufacturing and transport. The connector with its multiple receptacles and clamping portions maintains cable positions without tangling, and can be easily removed when not needed, thus solving the contradiction between forming wiring harnesses and preventing cable entanglement.
2Ease of manufacture
If cables are manually handled and bundled, then wiring harnesses can be created, but the process is time-consuming and labor-intensive
Solution Approach 1:
The transport connector enables self-service by allowing cables to be automatically inserted into receptacles and clamped without manual handling. The cables can be fed through the clamping portions automatically, and the connector maintains their positions during transport and storage, eliminating the need for time-consuming manual bundling operations.
3Stability of the object's composition
If cables are transported separately, then tangling is prevented, but mechanical connection and transport efficiency are reduced
Solution Approach 1:
The transport connector divides the cable management system into separate functional segments: individual receptacles for holding cable contacts and clamping portions for securing cables. This segmentation allows cables to be independently positioned and secured while being transported together as a group, maintaining separation benefits while achieving transport efficiency.
4Productivity
If automated insertion is implemented, then manufacturing speed increases, but device complexity increases
Solution Approach 1:
The transport connector applies local quality by providing different functional features at different locations: receptacles with insertion openings for automated contact element insertion, and clamping portions with gaps for cable securing. Each local feature is optimized for its specific function, enabling automated insertion without requiring overall system complexity.
Data Source
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AI summary
The invention relates to a transport connector (10), a system (5) and a method for manufacturing a cable harness (300), wherein the transport connector (10) has a first receptacle (25), a second receptacle (30), a first clamping section (35) and a second clamping section (40), wherein the transport connector (10) extends along a longitudinal direction between a first longitudinal side (60) and a second longitudinal side (65) arranged opposite the first longitudinal side (60), wherein the first receptacle (25) extends in a longitudinal direction and wherein the first clamping section (35) adjoins the first receptacle (25) in a longitudinal direction on the side facing the first longitudinal side (60), wherein the first clamping section (35) has a first clamping receptacle (100) that extends through in a longitudinal direction.wherein the second receptacle (30) extends longitudinally and the second clamping section (40) adjoins the second receptacle (30) opposite the first clamping section (35) in the longitudinal direction, wherein the second clamping section (40) has a second clamping receptacle (160) that extends longitudinally.