Project Details
This project focused on a harness that must remain serviceable while operating in a demanding environment at the front of the vehicle.
The harness is exposed to vibration and weather and is linked to critical safety features, making durability, packaging and manufacturability important.
Q5D used a technique of laying wires onto a sheet of Noise, Vibration and Harshness tape, using the sticky surface to retain wires and components during assembly.
A second sheet of NVH tape encapsulates the assembly before stiffening, mounting and protective elements are added. The final step is to cut the shape to create a low-profile, flexible harness.
The resulting part uses the same or similar materials as the harness it replaces, while introducing a more automated method of assembly. It was designed in CAD using geometry provided by the bumper and created using Q5D’s SQ25.
Key Attributes
| Annual Production | 30,000 / cell |
| Footprint / cell | 4m2 (cell only) |
| Takt time | <12mins/bumper |
Results / Benefits
- Low-profile flexible harness
- Direct replacement for a heavier conventional harness
- Uses familiar materials in a new assembly method
- Supports serviceability
- Suited to exposed automotive environments
- Designed from CAD geometry for repeatable manufacture
