Electrical Wire Length Calculation Using Reference Cross Sections

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Solution Overview

Problem

In the wire harness manufacturing process, determining the appropriate electrical wire length is challenging, leading to issues such as connectors not reaching fixtures, excessive tension, or wire entanglement, necessitating a method to calculate wire length before modeling to reduce time and effort.

Innovation Solution

An electrical wire length output method using an analyzer that calculates wire length by inputting reference cross sections and passing points, including cavity, node, and segment reference cross sections, to determine section wire lengths and output the total wire length, allowing for accurate pre-modeling calculations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If electrical wire length is set manually by analyst through trial and error, then modeling accuracy can be achieved, but time and effort are excessively consumed

Engineering Contradiction:

Improveelectrical wire length accuracyVSAvoidtime for setting wire length

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by calculating the electrical wire length before the modeling process begins. The calculation unit computes the required wire length based on connector positions and wire specifications in advance, allowing the analyst to directly use the calculated value without time-consuming trial and error adjustments during modeling.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the manual mechanical adjustment process with an automated calculation system. Instead of manually setting and adjusting wire lengths through trial and error, the system automatically calculates the precise wire length using computational algorithms based on geometric relationships between connectors and wire characteristics.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If electrical wire length is set too short, then connector reaches fixture, but excessive tension is applied to wire

Engineering Contradiction:

Improveconnector positioning accuracyVSAvoidwire tension stress

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The patent applies feedback by using the calculated wire length information to adjust and optimize the modeling parameters. The calculation results provide feedback on the appropriate wire length that prevents excessive tension while ensuring proper connector positioning, allowing the system to self-correct and avoid harmful stress conditions.

Inventive Principle:

Principle #23Feedback

3Ease of operation

If electrical wire length is set too long, then connector reaches fixture easily, but excessive curvature and entanglement occur

Engineering Contradiction:

Improveconnector installation easeVSAvoidwire curvature

Core Design Contradiction:

Ease of operationVSShape

Solution Approach 1:

The patent applies preliminary action by determining the optimal wire length before modeling, preventing excessive curvature and entanglement issues. By calculating the precise required length in advance, the system ensures the wire is neither too long (causing curvature) nor too short (causing tension), eliminating the need for manual adjustment and re-modeling.

Inventive Principle:

Principle #10Preliminary action

4Reliability

If trial and error method is used to set wire length, then appropriate value can be determined, but modeling time increases significantly

Engineering Contradiction:

Improvewire length appropriatenessVSAvoidmodeling efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces the manual trial-and-error mechanical process with an automated calculation system. The calculation unit computes the appropriate wire length directly using algorithms that consider connector positions, wire specifications, and geometric relationships, eliminating the need for repeated modeling attempts and significantly improving productivity while maintaining reliability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent applies self-service by enabling the system to automatically determine the appropriate wire length without requiring manual intervention or trial and error. The calculation unit independently computes the optimal length based on input parameters, making the system self-sufficient and eliminating the time-consuming iterative process that previously required analyst involvement.

Inventive Principle:

Principle #25Self-service

Data Source

PatentUS10288421B2Electrical wire length output method and storage medium in which electrical wire length output program is stored

Publication Date: 2019.05.14 YAZAKI CORP

AI summary

An electrical wire length output method according to the present invention sets a first cavity reference cross section, a first node reference cross section, and a second node reference cross section, and a second cavity reference cross section, calculates a section wire length in each section of the reference cross sections, and outputs the sum of the section wire lengths as the wire length of an electrical wire.