Automated Wire Harness Assembly with Ultrasonic Welding
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Summary
Problems
Conventional wire harness manufacturing processes are costly and labor-intensive, especially when routing paths for electric wires are complex or branched, as they require manual assembly of exterior members.
Innovation solutions
A method involving a harness assembling process with a mold release member to prevent sticking, and a joining process that automates the assembly of mesh-like and sheet-like exterior members around electric wires using ultrasonic welding or other techniques, eliminating the need for manual winding or insertion into corrugated tubes.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If manual assembly of exterior members is used for complex routing paths, then assembly quality is secured, but manufacturing cost increases and productivity decreases
Why choose this principle:
The patent replaces manual mechanical assembly operations with an automated joining system that uses ultrasonic welding or adhesive application mechanisms. The joining device automatically positions and attaches exterior members to electric wires along complex routing paths, eliminating the need for manual winding and attachment while maintaining consistent assembly quality through controlled processing parameters.
Principle concept:
If manual assembly of exterior members is used for complex routing paths, then assembly quality is secured, but manufacturing cost increases and productivity decreases
Why choose this principle:
The patent implements a self-positioning mechanism where the joining device automatically follows the routing path and positions exterior members without manual intervention. The system uses guides and positioning fixtures to ensure precise placement of exterior members on electric wires, enabling the assembly process to serve itself without continuous human operation.
Application Domain
Data Source
AI summary:
A method involving a harness assembling process with a mold release member to prevent sticking, and a joining process that automates the assembly of mesh-like and sheet-like exterior members around electric wires using ultrasonic welding or other techniques, eliminating the need for manual winding or insertion into corrugated tubes.
Abstract
A method for manufacturing a wire harness includes a harness assembling process, a mold release member installing process of, when a plurality of wire harnesses are assembled, each time the harness assembling process is ended, placing a mold release member on a wire harness, and a joining process of joining components of the wire harness together for each wire harness. The harness assembling process includes a first outer layer installing process of installing an exterior member as one outer layer on a jig plate, an inner layer installing process of routing a protection target part of at least one routed electric wire to the exterior member as the one outer layer, and a second outer layer installing process of overlaying an exterior member as another outer layer on the protection target part and the exterior member.