Wire Splice Housing With Funnels for Faster Harness Crimping
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Solution Overview
Problem
Conventional wire splicing methods face inefficiencies and performance compromises due to intricate assembly processes, tooling requirements, and limitations in accommodating diverse wire types and sizes, leading to labor-intensive and slow production in harness manufacturing.
Innovation Solution
A wire splice assembly comprising a wire splice terminal with crush barrels and a housing with funnels for guiding wires, integrated with a carrier strip for easy handling, and optional heat shrink sleeves for moisture protection, allowing for efficient and reliable connection of wires using crimping tools or machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional wire splicing methods are used, then wire connections can be made, but the assembly process becomes intricate and labor-intensive
Solution Approach 1:
The wire splice integrates multiple components (terminal, housing, funnels, carrier strip) into a single pre-assembled unit. This merging eliminates the need for intricate step-by-step assembly operations, allowing harness makers to simply insert the pre-assembled splice into the housing, thereby reducing labor intensity and assembly complexity while maintaining manufacturing ease
Solution Approach 2:
The wire splice is pre-assembled with the terminal, housing, and carrier strip integrated before reaching the final application point. This preliminary assembly of critical components resolves the contradiction by preparing the complex structure in advance, so that final installation requires minimal manipulation and no complex assembly steps at the point of use
2Productivity
If hand tools are used to connect wire splice products, then connections can be made, but production becomes slow and labor intensive
Solution Approach 1:
The integration of the terminal, housing, and carrier strip into a single pre-assembled unit eliminates the need for multiple hand tool operations. The unified structure allows machine-based insertion and connection, enabling high-volume automated production while maintaining ease of connection through the simplified single-unit insertion process
Solution Approach 2:
The wire splice design enables self-connection through the integrated carrier strip and housing structure that guides and secures the terminal automatically. This self-service capability eliminates the need for manual tool manipulation, allowing both hand operation and machine automation to achieve fast connections without complex tooling
3Productivity
If mass production machines are used to create spliced leads, then production volume increases, but loose piece splice elements become difficult to handle
Solution Approach 1:
The carrier strip merges multiple wire splice units into a single handled assembly, allowing mass production machines to process multiple splices simultaneously. This merging maintains ease of handling by providing a unified structure that can be gripped and manipulated as one unit, even as production volume increases through automated processes
Solution Approach 2:
The splice elements are pre-integrated with the carrier strip in a fixed configuration before mass production processing. This preliminary integration resolves the handling difficulty by establishing stable, predetermined positions of all components, making the entire assembly easy to handle and process in high-volume manufacturing environments
4Productivity
If tape is used to hold splice elements together, then assembly is possible, but production is slowed by improper positioning or handling
Solution Approach 1:
The carrier strip merges the function of positioning and holding splice elements into a single integrated structural component. This eliminates the separate tape element and its associated handling complexities, allowing production to proceed efficiently without the positioning and handling issues that arise when using adhesive tapes to secure splice components
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
Facilitates repeatable and efficient wire harness production by simplifying assembly, accommodating various wire sizes, and ensuring secure electrical connections with improved manufacturability and material handling.
Implementation Method 1
The wire tube has a first crush barrel at the first end configured to crimp to the first wire. The wire tube has a second crush barrel at the second end configured to crimp to the second wire.
Implementation Method 2
The wire spice assembly includes a first heat shrink sleeve coupled to the first end of the wire splice housing configured to be heat shrink applied to the first wire. The wire spice assembly includes a second heat shrink sleeve coupled to the second end of the wire splice housing configured to be heat shrink applied to the second wire.
Data Source
AI summary
A wire splice assembly includes a wire splice having a wire splice terminal and a wire splice housing holding the wire splice terminal. The wire splice terminal includes a wire tube extending between a first end configured to receive an end of a first wire and a second end configured to receive an end of a second wire. The wire tube has crush barrels at the ends configured to crimp to the wires. The wire splice housing includes a cavity receiving the wire splice terminal. The wire splice housing includes a first funnel at a first end configured to guide the first wire to the first end of the wire splice terminal. The wire splice housing includes a second funnel at a second end configured to guide the second wire to the second end of the wire splice terminal. The wire spice assembly includes a carrier strip integral with the wire splice housing extending from the wire splice housing for connecting the wire splice housing to other wire splices. The wire splice housing is configured to be singulated from the carrier strip.