Wiring Harness with Variable Wire Lengths for Terminal Processing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional wiring harness manufacturing processes require additional attachment of insulated electric wires to reach distant mounting locations, increasing man-hour costs due to uniform wire lengths and the need for additional connections.
Innovation Solution
A wiring harness with electric wires of varying lengths, where a conductive sheet and a protection member, such as a tape or sheet, cover the bundle, allowing for different extension lengths to match specific mounting locations, reducing the need for additional wire attachments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If all electric wires are cut to the same length during terminal processing, then the manufacturing process is simplified, but additional insulated electric wires must be attached to reach distant mounting locations, increasing man-hour costs
Solution Approach 1:
The patent applies local quality by making each electric wire have a different length tailored to its specific mounting location requirements. The first electric wire has a first length suitable for a first mounting location, while the second electric wire has a second length suitable for a second mounting location. This localized customization eliminates the need for additional extension wires at distant mounting locations, thereby reducing terminal processing man-hours while maintaining manufacturing simplicity through pre-configured wire lengths.
2Ease of operation
If the sheath and shield layer are removed for terminal processing, then terminal access is enabled, but additional wires must be attached for distant mounting locations, increasing complexity
Solution Approach 1:
The patent applies preliminary action by pre-configuring each electric wire with its required length before the wiring harness assembly is completed. The wires are bundled together with the protection member during manufacturing, with each wire's extending portion already cut to its final required length. This preliminary configuration ensures that when the sheath and shield layer are removed for terminal processing, each wire is ready for direct connection without requiring additional extension wires, thereby reducing device complexity.
3Ease of manufacture
If uniform wire lengths are used, then manufacturing is easier, but wires cannot reach distant mounting locations without additional attachments
Solution Approach 1:
The patent applies local quality by customizing the length of each electric wire according to its specific mounting location requirements. The first electric wire has a first length optimized for reaching a first mounting location, while the second electric wire has a second length optimized for reaching a second mounting location. This localized length customization provides mounting location flexibility while maintaining manufacturing simplicity through pre-configured wire lengths during the bundling process.
Solution Approach 2:
The patent applies parameter changes by varying the length parameter of each electric wire in the bundle. Instead of using a uniform wire length, the patent specifies different lengths for different wires based on their destination mounting locations. This parameter variation enables the wiring harness to adapt to different mounting configurations while the protection member still covers all wires uniformly during manufacturing, maintaining ease of manufacture.
Data Source
AI summary
Provided is a wiring harness and a method of producing the wiring harness which can reduce the man-hour in terminal processing. A shield cable includes a bundle of electric wires formed by bundling a plurality of signal wires and a drain wire together, and a protection tape wound around the bundle of electric wires. Extending portions of the plurality of signal wires and an extending portion of the drain wire have two different lengths from a terminal of the protection tape.