Method and system for installing a wire harness into a vehicle

Abstract

The invention provides a method and a system for installing a wire harness into a vehicle. A method for installing a wire harness in a vehicle includes: coupling at least one module and the wire harness to a fixture to form a structure; moving the structure to the vehicle; the module and the wire harness are separated from the fixing device; coupling the module and the wire harness to the vehicle; and removing the fixture from the vehicle.

Description

Technical Field

[0001] This disclosure relates to a method and system for installing a wiring harness into a vehicle. Background Technology

[0002] The statements in this section are provided only as background information in connection with this disclosure and may not constitute prior art.

[0003] Industrial robots are already used in a variety of manufacturing operations, including, for example, welding and moving parts from one location to another, such as retrieving parts from a storage location and moving them to an assembly station. For example, automating the movement of some vehicle parts, such as wiring harnesses, can be challenging due to a lack of proper handling of parts and mechanical repeatability.

[0004] This disclosure addresses these problems related to automating the handling of components, as well as other problems related to handling said components. Summary of the Invention

[0005] This section provides a general overview of this disclosure and is not a full disclosure of its entire scope or all its features.

[0006] In one form, this disclosure provides a method for mounting a wiring harness to a vehicle. The method includes: coupling at least one module and the wiring harness to a fixing device to form a structure; moving the structure to the vehicle; separating the module and the wiring harness from the fixing device; coupling the module and the wiring harness to the vehicle; and removing the fixing device from the vehicle.

[0007] In a variation of the method described in the above paragraphs, which can be implemented individually or in any combination: the method further includes: separating the module and the wiring harness from the fixing device while simultaneously coupling the module and the wiring harness to the vehicle; connecting at least one connector of the wiring harness to at least one terminal of the module before moving the structure to the vehicle; aligning the wiring harness and the module within the vehicle after moving the structure to the vehicle; the structure being a rigid structure; coupling the module and the wiring harness to the vehicle including mounting features for installing the module and the wiring harness into the vehicle; and coupling the module and the wiring harness... The connection to the fixing device occurs at a first position; the connection of the module and the wiring harness to the vehicle occurs at a second position, the first position being different from the second position; the connection of the module and the wiring harness to the vehicle includes: connecting a first portion of the module and the wiring harness to the first position of the vehicle and, after the first portion of the module and the wiring harness has been connected to the first position of the vehicle, connecting a second portion of the wiring harness to the second position of the vehicle; and the first position of the vehicle is the rear region of the vehicle, and the second position of the vehicle is the side region of the vehicle.

[0008] In another form, this disclosure provides a method for installing a wiring harness into a vehicle. The method includes: coupling a plurality of modules and the wiring harness to a fixing device to form a rigid structure; moving the rigid structure to the vehicle; separating the plurality of modules and the wiring harness from the fixing device; connecting the plurality of modules and the wiring harness to the vehicle; and removing the fixing device from the vehicle. Coupling the plurality of modules and the wiring harness to the vehicle includes coupling a first portion of the plurality of modules and the wiring harness to a first location in the vehicle and connecting a second portion of the wiring harness to a second location in the vehicle.

[0009] In a variation of the method described in the above paragraphs, which can be implemented individually or in any combination: the separation of the plurality of modules and the wiring harness from the fixing device and the coupling of the plurality of modules and the wiring harness to the vehicle occur simultaneously; before moving the rigid structure to the vehicle, at least one connector of the wiring harness is connected to a corresponding terminal of one of the plurality of modules; after moving the rigid structure to the vehicle, the wiring harness and the plurality of modules are aligned within the vehicle; coupling the plurality of modules and the wiring harness to the vehicle includes mounting features for installing the plurality of modules and the wiring harness into the vehicle; the first position is different from the second position; and after the first portion of the plurality of modules and the wiring harness has been coupled to the first position of the vehicle, the second portion of the wiring harness is coupled to the second position of the vehicle.

[0010] In another embodiment, this disclosure provides a system for mounting a wiring harness into a vehicle. The system includes a fixing device, at least one robot, and a controller. The fixing device includes at least one module coupled thereto. The controller communicates with the robot and is configured to: instruct the robot to attach the wiring harness to the fixing device including the at least one module to form a structure; instruct the robot to move the structure to the vehicle; instruct the robot to detach the module and the wiring harness from the fixing device; instruct the robot to attach the module and the wiring harness to the vehicle; and instruct the robot to move the fixing device from the vehicle.

[0011] In a variation of the method described in the above paragraphs, which can be implemented individually or in any combination: the structure is a rigid structure; the robot includes: a first robot configured to connect the wiring harness to the fixing device; and a second robot configured to move the structure to the vehicle; and connecting the module and the wiring harness to the vehicle includes connecting a first portion of the module and the wiring harness to a first position of the vehicle and connecting a second portion of the wiring harness to a second position of the vehicle after the first portion of the module and the wiring harness has been connected to the first position of the vehicle.

[0012] Further applicability will become apparent from the description provided herein. It should be understood that the descriptions and specific examples are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0013] To better understand this disclosure, various forms of the disclosure will now be described by way of example with reference to the accompanying drawings, in which:

[0014] Figure 1A It is a perspective view of a system for disposing of vehicle components according to the principles of this disclosure, wherein wiring harness components of the components are disposed on a working surface.

[0015] Figure 1B It is a perspective view of a component fixed to a vehicle according to the principles of this disclosure;

[0016] Figure 2 yes Figure 1A A perspective view of the system's fixing device;

[0017] Figure 3 It is fixed to the fixed device. Figure 1A A perspective view of the wire harness component shown;

[0018] Figure 4A and Figure 4BThis is a perspective view of a robot disassembling one segment of the wire harness component in Figure 1 from another segment and moving that segment to a fixing device;

[0019] Figure 5 This is a perspective view of the electrical connector of the wiring harness component in Figure 1, which is connected to the vehicle module component of the vehicle.

[0020] Figure 6 This is a perspective view of the electrical connector of the wiring harness component in Figure 1, which is connected to the vehicle module component of the vehicle.

[0021] Figure 7 Figure 1 is a perspective view of another robot system that moves a structure including components and fixing devices to a vehicle according to the principles of this disclosure;

[0022] Figure 8 yes Figure 7 The robot aligns the structural components with the perspective view of the vehicle;

[0023] Figure 9A and Figure 9B It connects the components to the vehicle. Figure 7 A perspective view of the robot;

[0024] Figure 10 yes Figure 7 The robot will Figure 2 A perspective view of the fixing device being moved back to the working surface;

[0025] Figure 11 It is to demonstrate the teachings of this disclosure. Figure 1A and Figure 1B A schematic block diagram of the system components; and

[0026] Figure 12 It describes the treatment based on the teachings of this disclosure. Figure 1A and Figure 1B The flowchart of the algorithm for the components of the system.

[0027] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of this disclosure in any way. Detailed Implementation

[0028] The following description is merely exemplary in nature and is not intended to limit this disclosure, its application, or its uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0029] refer to Figure 1AThe present invention illustrates a system 10 for disposing of one or more vehicle parts 12. Disposal of vehicle parts 12 may include retrieving vehicle parts 12 from a part support (e.g., a pad holder), placing vehicle parts 12 onto a work surface 16, manipulating parts of vehicle parts 12 on the work surface 16, and / or installing vehicle parts 12 into a machine 17 (e.g., a vehicle). System 10 allows for the disposal of vehicle parts 12 with minimal human intervention. In this way, the disposal of vehicle parts 12 can be automated to, for example, increase productivity, reduce cycle time, and reduce variability and error. In the example shown, vehicle parts 12 include electrical components, such as wiring harnesses. That is, wiring harnesses tend to be flexible, complex, and highly variable from one part to the next, making the installation of wiring harnesses into machine 17 potentially difficult to automate. System 10 of this disclosure provides adaptation to vehicle parts 12, such as wiring harnesses, to better support automation. It should be understood that vehicle parts 12 may be other parts of a vehicle besides wiring harnesses.

[0030] refer to Figure 1A System 10 may include vehicle component 12 (only one shown in the figure), fixture 14, one or more robots 22a, 22b, and controller 26. Figure 11 Each vehicle component 12 can be moved from a component support (not shown) to a mounting device 14. An example of a system for moving a vehicle component 12 from a component support to a mounting device 14 is described in U.S. Patent Application No. 18 / 909,210, filed October 8, 2024, entitled “SYSTEM FOR HANDLING A COMPONENT OF AVEHICLE,” the contents of which are incorporated herein by reference in their entirety. References Figure 3 Each vehicle component 12 includes a body or housing 28 and a plurality of collars 30a, 30b, 30c, 30d, 31a, 31b. The body 28 may be made of a rigid material (e.g., metal or plastic) and may house electrical components 21 (e.g., flexible wires). In the example shown, the body 28 is hollow and has a square shape. In some forms, the body 28 may have a circular shape, a rectangular shape, or any other suitable shape that may house electrical components.

[0031] In the example shown, the main body 28 includes multiple segments 28a, 28b that are movable relative to each other. For example, when the vehicle component 12 moves from the part support (not shown) to the fixture 14, segments 28a, 28b can be coupled to each other (e.g., folded onto each other). In this way, the movement of the vehicle component 12 to the fixture 14 is facilitated. Once the vehicle component 12 is coupled to the fixture 14, the segments 28a, 28b of the vehicle component 12 can be separated from each other (e.g., unfolded) using the robot 22a and positioned relative to each other at predetermined locations for further processing. In the example shown, once the vehicle component 12 is coupled to the fixture 14, segment 28b of the vehicle component 12 is separated or detached from segment 28a and positioned relative to segment 28a. Segment 28b can be positioned relative to segment 28a at, for example, a vertical angle, an obtuse angle, or an acute angle.

[0032] In the example shown, once vehicle component 12 is coupled to fixture 14, segments 28a and 28b can be spaced apart from each other. In the example shown, the length of segment 28a of vehicle component 12 is greater than the length of segment 28b of vehicle component 12. In some forms, the length of segment 28a of vehicle component 12 may be equal to or less than the length of segment 28b of vehicle component 12. It should be understood that electrical components (e.g., wires) extend through segments 28a and 28b of body 28 and may have ends fixed to body 28, as will be described in more detail below. It should also be understood that although this disclosure discloses a body 28 having two segments 28a and 28b that are movable relative to each other, body 28 may include more than two segments that are movable relative to each other without departing from the scope of this disclosure.

[0033] A collar 30a may be coupled to the opposite end of a segment 28a of vehicle component 12 and may be configured to attach vehicle component 12 to a part support (not shown). An example of such a collar is disclosed in U.S. Patent Application No. 18 / 909,210, filed October 8, 2024, entitled “SYSTEM FORHANDLING A COMPONENT OF A VEHICLE,” the contents of which are incorporated herein by reference in their entirety. A collar 30b may be coupled between collars 30a to a segment 28a of vehicle component 12 and may be configured to allow a robot (not shown) to grasp vehicle component 12 for movement from part support to fixture 14. An example of such a collar is disclosed in U.S. Patent Application No. 18 / 909,210, filed October 8, 2024, entitled “SYSTEM FORHANDLING A COMPONENT OF A VEHICLE,” the contents of which are incorporated herein by reference in their entirety.

[0034] One or more collars 30c may be coupled to segment 28b of vehicle component 12 and may be configured to allow robot 22a to grasp segment 28b of vehicle component 12 and detach segment 28b from segment 28a. An example of such collars is described in U.S. Patent Application No. 18 / 909,203, filed October 8, 2024, entitled “SYSTEM FOR HANDLING ELECTRICAL COMPONENTS FOR VEHICLE,” the contents of which are incorporated herein by reference in their entirety. One or more collars 30d may be coupled to corresponding segments 28a, 28b of vehicle component 12 and may be configured to removably couple connector 21a of electrical component 21 to body 28 of vehicle component 12. In the example shown, collar 30d is coupled to segment 28b of vehicle component 12 and may couple connector 21a of electrical component 21 to segment 28b. In this manner, when vehicle component 12 moves from part support (not shown) to fixing device 14 and when segment 28b separates from segment 28a, connector 21a is secured to body 28, as described above. An example of such a collar is disclosed in U.S. Patent Application No. 18 / 909,203, filed October 8, 2024, entitled “SYSTEM FOR HANDLING ELECTRICAL COMPONENTS FOR VEHICLE,” which is commonly owned by and incorporated herein by reference in its entirety.

[0035] The collar 31 can be attached to sections 28a, 28b of the vehicle component 12 and can be configured to attach the vehicle component 12 to the machine 17. The collar 31 may include one or more of clips, tabs, and fasteners to attach the vehicle component 12 to the machine 17. In one embodiment, the collar 31 can attach the vehicle component 12 to different areas of the machine 17. In the example shown, the collar 31 attaches the vehicle component 12 to the side areas (e.g., lower side beams) and the rear area of ​​the machine 17. It should also be understood that, for example, the collar 31 can attach the vehicle component 12 to the front area and / or the floor area of ​​the machine 17. An example of such a collar is disclosed in U.S. Patent Application No. 18 / 909,205, filed October 8, 2024, entitled “RETENTION ASSEMBLY FOR COUPLING WIRINGHARNESS TO VEHICLE HAVING ELECTRICAL GROUND”, the contents of which are incorporated herein by reference in their entirety.

[0036] refer toFigure 2 and Figure 3 The fixing device 14 is removably coupled to the working surface 16, allowing the fixing device 14 to be gripped by the robot 22b. That is, the fixing device 14 can be supported on one or more rails or beams 32, which can be fixed to the working surface 16 such that the fixing device 14 is spaced apart from the working surface 16, thereby allowing the robot 22b to grip the fixing device 14 and remove it from the working surface 16, as will be described in more detail below. In some forms, the fixing device 14 can be removably coupled directly to the working surface 16. The fixing device 14 includes a first component 34, a second component 36, an intermediate component 38, a plurality of brackets or retaining features 40, and a plurality of modular support members 42.

[0037] The first component 34 may be made of a rigid material (e.g., metal or plastic) and may support the vehicle component 12 (e.g., segment 28a of the vehicle component 12) as it moves to the working surface 16. In the example shown, the first component 34 has a square shape. In some forms, the first component 34 may have a circular shape, a rectangular shape, or any other suitable shape that may support the vehicle component 12. In some forms, the first component 34 may be solid. In other forms, the first component 34 may be hollow to reduce the weight of the fixing device 14. The second component 36 may be made of a rigid material (e.g., metal or plastic) and may support the vehicle component 12 (e.g., segment 28b of the vehicle component 12) as it moves to the working surface 16. In the example shown, the length of the first component 34 is greater than the length of the second component 36. In some forms, the length of the first component 34 may be equal to or less than the length of the second component 36. In the example shown, the second component 36 has a square shape. In some forms, the second component 36 may have a circular shape, a rectangular shape, or any other suitable shape that can support the vehicle component 12. In some forms, the second component 36 may be solid. In other forms, the second component 36 may be hollow to reduce the weight of the fixing device 14. In the example shown, the second component 36 extends in a different direction than the first component 34. In some forms, the first component 34 and the second component 36 may extend in the same direction. Although the first component 34 and the second component 36 are shown to have the same shape, it should be understood that in some configurations, the first component 34 and the second component 36 may have different shapes to support different parts of the vehicle component 12 or parts fixed to the fixing device 14.

[0038] Intermediate component 38 is positioned between first component 34 and second component 36 and can guide and support a portion of electrical component 21. In this way, for example, when fixture 14 and vehicle component 12 move from work surface 16 to machine 17, entanglement of electrical component 21 is prevented. In the example shown, intermediate component 38 has a polygonal shape with multiple flat sides. In this way, segments 28a, 28b can engage the flat sides of intermediate component 38 when vehicle component 12 is coupled to fixture 14. In some forms, intermediate component 38 may include a circular or arcuate shape. In the example shown, intermediate component 38 is located at a corner of fixture 14, where first component 34 and second component 36 extend in different directions. In this way, electrical component 21, as well as first component 34 and second component 36, can be supported. For example, intermediate component 38 is also secured to first component 34 and second component 36 via welding, fasteners, or adhesives.

[0039] Multiple supports 40 are secured to a first component 34 and a second component 36, and may include openings configured to receive a vehicle component 12, thereby coupling the vehicle component 12 to the mounting device 14. The supports 40 are spaced apart from each other and may be positioned between one or more collars. In the example shown, each support 40 may include two shells or halves secured to components 34, 36 via fasteners. In some forms, components 34, 36 may be manufactured (e.g., additively manufactured or injection molded) as a single integral component to include the supports 40. Each opening includes a first or insertion portion and a second or holding portion. The first portion is the position where the vehicle component 12 is inserted into the support 40. The second portion is the position where the vehicle component 12 is held in the support 40. That is, the vehicle component 12 can be prevented from lateral movement when in the second portion, and can be prevented from downward movement when in the second portion. When in the second portion of the opening, gravity prevents the vehicle component 12 from moving upward. In the example shown, the first portion tapers towards the second portion. In this way, the first portion can accommodate errors or misalignments in the initial positioning of the vehicle component 12 performed by a robot (not shown). When segments 28a and 28b of vehicle component 12 are received in the second part of bracket 40, segments 28a and 28b are positioned relative to and spaced apart from the first component 34 and the second component 36 of fixing device 14.

[0040] Each module support 42 is fixed to a corresponding section 28a, 28b of the fixing device 14 and can be configured to hold the corresponding vehicle module 46a, 46b. In one example, vehicle modules 46a, 46b may be engine control modules that control multiple systems of an internal combustion engine. In another example, vehicle modules 46a, 46b may be suspension modules that control the suspension and independently adjust the tension of each wheel. It should be understood that the module support 42 may support other vehicle modules used in the machine 17.

[0041] Each module support 42 includes a structure or housing to which vehicle modules 46a, 46b can be attached. For example, a robot (not shown) can attach vehicle modules 46a, 46b to the module support 42 with minimal human intervention, thereby increasing productivity and reducing cycle time. In the example shown, the module support 42 is secured to a second component 36 of the fixture 14 (e.g., by fasteners). In some forms, the module support 42 may be secured to a first component 34 of the fixture 14. In other forms, one or more module supports 42 may be secured to the first component 34 of the fixture 14, and one or more module supports 42 may be secured to the second component 36 of the fixture 14. Some module supports 42 may be directly secured to components 34, 36, and some module supports 42 may be secured to a column or beam 43, which in turn is directly secured to components 34, 36. 。 In this way, vehicle modules 46a and 46b can be positioned at different locations and angles relative to each other along the fixing device 14. It should be understood that vehicle modules 46a and 46b are coupled to module support 42 such that when the fixing device 14 is moved from the working surface 16 to the machine 17 via robot 22b, vehicle modules 46a and 46b are prevented from moving relative to the fixing device 14, as will be described in more detail below.

[0042] refer to Figure 1A , Figure 4A , Figure 4B , Figure 5 and Figure 6Robot 22a is configured to separate segments 28a, 28b of vehicle component 12 from each other on working surface 16 and to connect connector 21a of electrical component 21 to terminals 53 of vehicle modules 46a, 46b. Robot 22a includes a robot arm 50 and a robot gripper structure or device 52. Robot arm 50 includes multiple segments 50a connected to each other at joints, thereby allowing robot 22a to have multiple degrees of freedom. Robot arm 50 is also fixed to working surface 16 at a first end. In some variations, robot arm 50 includes an optional adapter (not shown) adapted for fixing to working surface 16. In some forms, robot 22a is separated from working surface 16 and is partially or fully autonomous, and is configured to move autonomously to working surface 16 as instructed by controller 26. In order to move itself autonomously, controller 26 is configured to control various movement systems of robot 22a based on position data obtained from one or more sensors. In the example application, the mobile system may include a propulsion system, a steering system for controlling the wheels, and sensors for providing location data may include GNSS sensors, imaging sensors, local location sensors, etc.

[0043] Robot gripper structure 52 is attached to robot arm 50 and configured to grip and move vehicle component 12 segments 28a, 28b. An example of such a collar is disclosed in U.S. Patent Application No. 18 / 909,203, filed October 8, 2024, entitled “SYSTEM FOR HANDLING ELECTRICAL COMPONENTS FOR VEHICLE”, the contents of which are incorporated herein by reference in their entirety.

[0044] refer to Figure 7 , Figure 8 , Figure 9A and Figure 9BRobot 22b is configured to move fixture 14 and vehicle component 12 from work surface 16 to machine 17, and to attach vehicle component 12 and control modules 46a, 46b to machine 17. That is, robot 22b engages fixture 14 to move fixture 14 and vehicle component 12 attached thereto from work surface 16 to machine 17. Robot 22b includes robot arm 60 and robot gripper structure or device 62. Robot arm 60 includes multiple segments 60a connected to each other at joints, thereby allowing robot 22b to have multiple degrees of freedom. In some forms, robot 22b is separate from work surface 16 and is partially or fully autonomous, and is configured to move autonomously to work surface 16 as instructed by controller 26. To move itself autonomously, controller 26 is configured to control various movement systems of robot 22b based on position data obtained from one or more sensors. In example applications, movement systems may include propulsion systems, steering systems for controlling wheels, and sensors for providing position data may include GNSS sensors, imaging sensors, local position sensors, etc. The robot gripper structure 62 is fixed to the robot arm 60 and configured to grip the fixing device 14 and move it from the work surface 16 to the final vehicle assembly line 76.

[0045] refer to Figure 11 The controller 26 communicates with robots 22a and 22b and can monitor and control the operation of robots 22a and 22b based on the received data. In one example, the controller 26 communicates with robots 22a and 22b using wired or wireless communication protocols (e.g., Bluetooth®, cellular, Wi-Fi, Near Field Communication (NFC), Ultra Wideband (UWB), etc.).

[0046] System 10 also includes vision sensors 64a and 64b. For example, vision sensors 64a and 64b are respectively mounted on the respective robots 22a and 22b and can communicate with controller 26 using wireless communication protocols (e.g., Bluetooth®, cellular, Wi-Fi, NFC, UWB, etc.). Each vision sensor 64a and 64b collects visual image data and transmits it to controller 26. Based on the visual image data, controller 26 provides instructions to robots 22a and 22b to operate them. More specifically, controller 26 provides instructions to operate robots 22a and 22b to move segments 28a and 28b of vehicle component 12 relative to each other, and to move fixture 14, vehicle component 12, and control modules 46a and 46b to machine 17 based on the visual image data collected by vision sensors 64a and 64b.

[0047] In one embodiment, vision sensors 64a and 64b are configured with an object detection algorithm trained to identify collars 30c and 30d on vehicle component 12 and mounting features associated with machine 17 based on images collected by vision sensors 64a and 64b. The object detection algorithm is an image processing technique such as Canny edge detection or deep learning. In another embodiment, controller 26 is configured with an object detection algorithm and locates collars 30c and 30d on vehicle component 12 and mounting features of machine 17 based on image data from a positioning system (not shown). In one embodiment, the visual image data includes coordinate data, such as two-dimensional or three-dimensional coordinate data, that the positioning system is configured to process into a global coordinate system. Based on the positioning performed by the positioning system, controller 26 is configured to identify objects and their positions in the visual image data.

[0048] System 10 may also include sensors 66a and 66b. Sensors 66a and 66b may be associated with (e.g., mounted on) their respective robots 22a and 22b, and may communicate with controller 26 using wireless communication protocols (e.g., Bluetooth®, cellular, Wi-Fi, NFC, UWB, etc.). Each sensor 66a and 66b measures the force or pressure applied to robots 22a and 22b and transmits the data to controller 26. Based on the force or pressure data, controller 26 provides instructions to robots 22a and 22b to operate them.

[0049] refer to Figure 12 An example control algorithm 100 is shown for moving segments 28a, 28b of vehicle component 12 relative to each other and for moving vehicle component 12, fixture 14, and control modules 46a, 46b to machine 17. As described above, processing can begin once vehicle component 12 has moved from part support (not shown) to fixture 14. At 104, the control algorithm uses controller 26 to instruct a robot (not shown) to engage one or more vehicle modules 46a, 46b to fixture 14. It should be understood that vehicle modules 46a, 46b may be engaged to fixture 14 before or after vehicle component 12 moves to fixture 14. It should also be understood that one of robots 22a, 22b may engage vehicle modules 46a, 46b to fixture 14.

[0050] At point 108, the control algorithm uses controller 26 to instruct robot 22a to unfold or disassemble segments 28a and 28b of vehicle component 12. Figure 4A and Figure 4BThat is, during transport from the component support (not shown) to the fixture 14, segments 28a, 28b can be folded or attached to each other to facilitate transport. Once the vehicle component 12 is attached to the fixture 14, segments 28a, 28b can be disassembled for further processing of the vehicle component 12. At 112, the control algorithm uses controller 26 to instruct robot 22a to connect one or more connectors 21a of electrical component 21 to the corresponding terminals 53 of vehicle modules 46a, 46b. Figure 5 and Figure 6 In this way, electrical component 21 is electrically connected to vehicle modules 46a and 46b. It should be understood that vision sensors 64a and 66a facilitate the connection of connector 21a to the corresponding terminals 53 of vehicle modules 46a and 46b. Once connector 21a is connected to the corresponding terminals 53, the fixture 14, vehicle modules 46a and 46b, and vehicle component 12 form a rigid structure 70.

[0051] At point 116, the control algorithm uses controller 26 to instruct robot 22b to move rigid structure 70 to machine 17. Figure 7 In this way, the parts of the rigid structure 70 (e.g., connector 21a, vehicle modules 46a, 46b, vehicle component 12, fixture 14) are held in place as the rigid structure 70 moves to the machine 17. That is, the rigid structure 70 is formed at a working surface 16, which can be located away from the final vehicle assembly line where the machine 17 is located (e.g., at a different location). In this way, the rigid structure 70 can be constructed away from the final vehicle assembly line and then moved to the machine 17 on the final vehicle assembly line. Offline construction of electrical components 21 and vehicle modules 46a, 46b onto the fixture 14 allows for longer cycle times per robot operation, thus enabling the use of smaller robots. Offline construction of electrical components 21 and vehicle modules 46a, 46b onto the fixture 14 also allows for offline verification of electrical connections, preventing rework on the final vehicle assembly line. Offline construction of electrical components 21 and vehicle modules 46a, 46b onto the fixture 14 further prevents electrical components from becoming entangled with features and parts on the machine 17.

[0052] At 120, the control algorithm uses controller 26 to instruct robot 22b to align vehicle modules 46a, 46b and vehicle component 12 with machine 17. Figure 8It should be understood that vision sensors 64b and 66b facilitate the alignment of vehicle modules 46a, 46b and vehicle component 12 to machine 17. At 124, the control algorithm uses controller 26 to instruct robot 22b to move rigid structure 70 in a predetermined pattern to disengage vehicle modules 46a, 46b and vehicle component 12 from fixture 14 and to attach vehicle modules 46a, 46b and vehicle component 12 to machine 17. Figure 9A and Figure 9B It should be understood that the separation of vehicle modules 46a, 46b and vehicle component 12 from the fixing device 14 and the coupling of vehicle modules 46a, 46b and vehicle component 12 to the machine 17 can occur simultaneously. Coupling vehicle modules 46a, 46b and vehicle component 12 to the machine 17 may include mounting features for mounting vehicle modules 46a, 46b and vehicle component 12 onto the machine 17. In one form, the mounting features may include holes or slots formed in the machine 17. In this way, protrusions, pins and / or tabs on vehicle modules 46a, 46b and collar 31 on vehicle component 12 can be securely received in the mounting features of the machine 17 to attach vehicle modules 46a, 46b and vehicle component 12 to the machine 17.

[0053] In the example shown, vehicle modules 46a, 46b and segment 28b can be attached to a first position of machine 17, and segment 28a can be attached to a second position of machine 17 different from the first position. For example, the first position can be a rear region of machine 17, and the second position can be a side region of machine 17 (e.g., a lower beam or sill). Vehicle modules 46a, 46b and segment 28b can be attached to the first position of machine 17 before segment 28a is attached to the second position. In this way, the control algorithm uses controller 26 to instruct robot 22b to move rigid structure 70 in a first predetermined pattern to attach vehicle modules 46a, 46b and segment 28b to the first position, and then instructs robot 22b to move rigid structure 70 in a second predetermined pattern to attach segment 28a to the second position. In some forms, vehicle modules 46a, 46b and segments 28a, 28b can be attached to machine 17 simultaneously. In other forms, the rigid structure 70 may include other components attached to the machine 17 in a predetermined order.

[0054] At point 128, the control algorithm uses controller 26 to instruct robot 22b to remove fixture 14 from machine 17. Figure 10Robot 22b can move the fixture 14 back to the working surface 16, where another vehicle component is attached, thereby repeating the process again. Although system 10 discloses two robots 22a, 22b (i.e., robot 22a for deploying segments 28a, 28b of vehicle component 12 and connecting electrical components 21 to modules 46a, 46b, and robot 22b for moving structure 70 to machine 17), system 10 may include a single robot performing the desired function.

[0055] Unless otherwise expressly indicated herein, all numerical values ​​indicating mechanical / thermal properties, percentage of composition, dimensions and / or tolerances or other characteristics should be understood as being modified by the words “about” or “approximately” when describing the scope of this disclosure. Such modification is desired for various reasons, including: industrial practice; material, manufacturing and assembly tolerances; and testing capabilities.

[0056] As used herein, the phrases A, B, and C at least one should be interpreted as using the non-exclusive logic "or" to represent logic (A or B or C), and should not be interpreted as meaning "at least one of A, at least one of B, and at least one of C".

[0057] In this application, the terms “controller” and / or “module” may refer to, be part of, or include the following: application-specific integrated circuit (ASIC); digital, analog, or mixed analog / digital discrete circuit; digital, analog, or mixed analog / digital integrated circuit; composable logic circuit; field-programmable gate array (FPGA); processor circuitry (shared, dedicated, or grouped) that executes code; memory circuitry (shared, dedicated, or grouped) that stores code executed by the processor circuitry; other suitable hardware components that provide the described functionality (e.g., an operational amplifier circuit integrator as part of a thermal flux data module); or combinations of some or all of the above, such as in a system-on-a-chip.

[0058] The term memory is a subset of the term computer-readable medium. As used herein, the term computer-readable medium does not cover transient electrical or electromagnetic signals propagated through a medium (such as on a carrier wave); therefore, the term computer-readable medium can be considered tangible and non-transient. Non-limiting examples of non-transient tangible computer-readable media include non-volatile memory circuits (such as flash memory circuits, erasable programmable read-only memory circuits, or mask read-only circuits), volatile memory circuits (such as static random access memory circuits or dynamic random access memory circuits), magnetic storage media (such as analog magnetic tape or digital magnetic tape or hard disk drives), and optical storage media (such as CDs, DVDs, or Blu-ray discs).

[0059] The apparatus and methods described in this application can be implemented, in part or in whole, by a dedicated computer created by configuring a general-purpose computer to perform one or more specific functions embodied in a computer program. Function blocks, flowchart components, and other elements described above serve as software specifications that can be translated into computer programs through the routine work of a technician or programmer.

[0060] The description in this disclosure is merely exemplary in nature, and therefore, variations thereof without departing from the spirit and scope of this disclosure are intended to be made within its scope. Such variations should not be considered as departing from the spirit and scope of this disclosure.

[0061] According to the present invention, a method for installing a wiring harness into a vehicle includes: coupling a plurality of modules and the wiring harness to a fixing device to form a rigid structure; moving the rigid structure to the vehicle; separating the plurality of modules and the wiring harness from the fixing device; coupling the plurality of modules and the wiring harness to the vehicle; and removing the fixing device from the vehicle, wherein coupling the plurality of modules and the wiring harness to the vehicle includes coupling a first portion of the plurality of modules and the wiring harness to a first location in the vehicle and coupling a second portion of the wiring harness to a second location in the vehicle.

[0062] In one aspect of the invention, the separation of the plurality of modules and the wiring harness from the fixing device and the connection of the plurality of modules and the wiring harness to the vehicle occur simultaneously.

[0063] In one aspect of the invention, the method includes connecting at least one connector of the wiring harness to a corresponding terminal of one of the plurality of modules before moving the rigid structure to the vehicle.

[0064] In one aspect of the invention, the method includes aligning the wiring harness and the plurality of modules within the vehicle after moving the rigid structure to the vehicle.

[0065] In one aspect of the invention, connecting the plurality of modules and the wiring harness to the vehicle includes an installation feature of mounting the plurality of modules and the wiring harness to the vehicle.

[0066] In one aspect of the invention, the first position is different from the second position.

[0067] In one aspect of the invention, after the first portion of the plurality of modules and the wiring harness has been connected to the first position of the vehicle, the second portion of the wiring harness is connected to the second position of the vehicle.

Claims

1. A method for installing a wiring harness into a vehicle, the method comprising: At least one module and the wiring harness are connected to a fixing device to form a structure; Move the structure to the vehicle; Separate the at least one module and the wiring harness from the fixing device; Connect the at least one module and the wiring harness to the vehicle; as well as Remove the fixing device from the vehicle.

2. The method of claim 1, wherein separating the at least one module and the wiring harness from the fixing device and connecting the at least one module and the wiring harness to the vehicle occur simultaneously.

3. The method of claim 1, further comprising connecting at least one connector of the wiring harness to at least one terminal of the at least one module before moving the structure to the vehicle.

4. The method of claim 1, further comprising aligning the wiring harness and the at least one module within the vehicle after moving the structure to the vehicle.

5. The method of claim 1, wherein the structure is a rigid structure.

6. The method of claim 1, wherein connecting the at least one module and the wiring harness to the vehicle includes mounting features of mounting the at least one module and the wiring harness to the vehicle.

7. The method of claim 1, wherein: The connection of the at least one module and the wiring harness to the fixing device occurs at a first position; and The connection of the at least one module and the wiring harness to the vehicle occurs at a second location, wherein the first location is different from the second location.

8. The method of claim 1, wherein connecting the at least one module and the wiring harness to the vehicle comprises connecting a first portion of the at least one module and the wiring harness to a first location of the vehicle and, after the first portion of the at least one module and the wiring harness has been connected to the first location of the vehicle, connecting a second portion of the wiring harness to a second location of the vehicle.

9. The method of claim 8, wherein the first position of the vehicle is the rear region of the vehicle, and the second position of the vehicle is the side region of the vehicle.

10. A system for installing a wiring harness into a vehicle, the system comprising: A fixing device, the fixing device including at least one module connected thereto; At least one robot; and A controller, which communicates with the at least one robot, is configured to: Instruct the at least one robot to connect the wiring harness to the fixing device including the at least one module to form a structure; Instruct the at least one robot to move the structure to the vehicle; Instruct the at least one robot to separate the at least one module and the wiring harness from the fixing device; Instruct the at least one robot to connect the at least one module and the wiring harness to the vehicle; as well as Instruct the at least one robot to move the fixed device from the vehicle.

11. The system of claim 10, wherein the structure is a rigid structure.

12. The system of claim 10, wherein the at least one robot comprises: A first robot, configured to connect the wiring harness to the fixing device; And a second robot, configured to move the structure to the vehicle.

13. The system of claim 10, wherein connecting the at least one module and the wiring harness to the vehicle comprises connecting a first portion of the at least one module and the wiring harness to a first location of the vehicle and, after the first portion of the at least one module and the wiring harness has been connected to the first location of the vehicle, connecting a second portion of the wiring harness to a second location of the vehicle.

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