Method for manufacturing a wiring harness based on an animation / GIF

Abstract

A method for manufacturing a wiring harness based on one or more GIF or animation based engineering files (106) is disclosed. A 1:1 scale engineering drawing of the wiring harness is converted into one or more GIF or animation based engineering files (106) by a format conversion module (104). The GIF or animation based engineering files (106) are distributed to a plurality of manufacturing units. Thereafter, the one or more GIF or animation based engineering files (106) are projected onto a reusable build plate (112) by a projection setup module (110). Various components of the wiring harness are fixed on the reusable build plate (112) by a jig. A quality check module (116) checks the accuracy of the component placement against the one or more GIF or animation based engineering files (106). Thereafter, a board test module (118) verifies the wiring harness assembled on the reusable build plate (112) in real time.

Description

Technical Field

[0001] This invention relates generally to the field of wire harnesses, and more specifically to methods for manufacturing wire harnesses. Background Technology

[0002] Wire harness manufacturing has historically relied on manual assembly techniques using paper engineering drawings to guide the process. These traditional methods require operators with high skills in accurately interpreting technical specifications, often resulting in inconsistent assembly quality and susceptibility to human error. The reliance on physical 1:1 scale drawings requires significant manual processing, including drawing preparation, printing, and frequent updates, inevitably slowing production cycles and increasing operating costs. Design revisions further complicate the process, as they necessitate reprinting and physically replacing drawings on assembly plates, leading to inefficient workflows and increased downtime. Furthermore, the lack of real-time data synchronization and automated instructions in these traditional methods hinders responsiveness to design changes and adaptability to evolving production demands, thus limiting overall manufacturing efficiency and scalability. These drawbacks highlight the technical challenges associated with existing wire harness manufacturing methods and underscore the need for improved solutions to enhance accuracy, reduce errors, and optimize the production process.

[0003] Therefore, a method based on animation / GIF to create wire harnesses is needed to alleviate the above drawbacks. Summary of the Invention

[0004] This invention is provided to describe aspects related to a method for manufacturing wire harnesses. The disclosed method includes creating 1:1 scale engineering drawings of the wire harness and then converting them into GIF- or animated files for enhanced visual guidance. The converted GIF- or animated files are stored and distributed to the manufacturing unit. The converted GIF- or animated engineering drawings are displayed on a reusable build plate to guide the assembly process. A component assembly module secures the wire harness components according to the guidance of the converted GIF- or animated engineering drawings. A quality inspection module verifies the placement of the components. An onboard testing module performs real-time verification of the assembled wire harnesses on the build plate. By providing wire harness drawings in the form of GIF- or animated files, this invention provides precise visual guidance, thereby reducing assembly errors and improving workflow efficiency.

[0005] In one aspect, a method for manufacturing wire harnesses is disclosed. This method includes the following steps: generating 1:1 scale engineering drawings of the wire harness by a drawing creation module; converting the engineering drawings into one or more GIF- or animation-based engineering files by a format conversion module operably linked to the drawing creation module for enhanced visual guidance; storing, managing, and distributing the converted GIF- or animation-based engineering files to multiple manufacturing units by a file management module integrated with Product Lifecycle Management (PLM) or Product Data Management (PDM); displaying the converted GIF- or animation-based engineering files on a reusable build plate by a projection setting module including a computer system and a projector to guide the assembly process; fixing the wire harness components according to the guidance of the converted GIF- or animation-based engineering files by a component assembly module including a reusable build plate equipped with multiple suction-and-grip or magnetic clamps; verifying the accuracy of component placement by a quality inspection module integrated with multiple sensors against the converted GIF- or animation-based engineering files; and performing real-time verification of the assembled wire harness on the reusable build plate by an onboard testing module.

[0006] Other aspects and advantages of the invention will become apparent from the following description taken in conjunction with the accompanying drawings, which illustrate the principles of the invention by way of example. Attached Figure Description

[0007] The accompanying drawings are incorporated in and form part of this specification and are intended to provide a further understanding of the general aspects of the system / method. These illustrative aspects of the system / method, along with the detailed description, illustrate the principles of the system. No further structural details are attempted beyond those necessary for a basic understanding of the system and its various practical applications. The following figures are included in the accompanying drawings:

[0008] Figure 1 A block diagram illustrating the modular operation of a method for manufacturing wire harnesses is shown.

[0009] Figure 2 The process flow associated with the steps of manufacturing wire harnesses is shown.

[0010] In the accompanying drawings, similar parts and / or features may have the same reference numerals. Furthermore, various parts of the same type may be distinguished by adding a letter after the reference numeral. If only the first reference numeral is used in the specification, the description applies to any of the similar parts and / or features having the same first reference numeral, regardless of the suffix.

[0011] List of reference numerals

[0012] 100-method

[0013] 102-Drawing Creation Module

[0014] 104-Format Conversion Module

[0015] 106 - Project files based on GIFs or animations

[0016] 108-File Management Module

[0017] 110-Projection Settings Module

[0018] 110a-Computer System

[0019] 110b-Projector

[0020] 112 - Reusable building board

[0021] 114-Component Assembly Module

[0022] 116-Quality Inspection Module

[0023] 118-Onboard Test Module

[0024] 120-Manufacturing Unit

[0025] 122-Central Server

[0026] 124-MES Server

[0027] 126-MES Terminal Detailed Implementation

[0028] Illustrative embodiments are described with reference to the accompanying drawings. Where it is convenient, the same reference numerals are used throughout the drawings to refer to the same or similar parts. Although examples and features of the disclosed principles have been described herein, modifications, adjustments, and other implementations are possible without departing from the spirit and scope of the disclosed embodiments. The following detailed description is to be considered exemplary only; the true scope and spirit are indicated by the appended claims.

[0029] Wire harness manufacturing has historically relied on manual assembly techniques guided by paper engineering drawings. These traditional methods require operators to possess a high level of skill in accurately interpreting technical specifications, often resulting in inconsistent assembly quality and susceptibility to human error. The reliance on physical 1:1 scale drawings requires significant manual processing, including drawing preparation, printing, and frequent updates, inevitably slowing production cycles and increasing operating costs. Design revisions further complicate the process, as they necessitate reprinting and physically replacing drawings on assembly plates, leading to inefficient workflows and increased downtime.

[0030] Furthermore, the lack of real-time data synchronization and automated instructions in these traditional methods hinders responsiveness to design changes and adaptability to evolving production demands, thus limiting overall manufacturing efficiency and scalability. These drawbacks highlight the technical challenges associated with existing wire harness manufacturing methods and underscore the need for improved solutions to enhance accuracy, reduce errors, and optimize the production process.

[0031] The disclosed method addresses this limitation by converting 1:1 scale engineering drawings of the wire harness into GIF- or animated engineering files. These GIF- or animated engineering files provide visual guidance for operators engaged in wire harness manufacturing. These files can be sent to different manufacturing units. The GIF- or animated engineering files are projected onto a reusable build plate equipped with multiple magnetic or adhesive clamps. Once the wire harness is assembled, its accuracy is verified by comparing the placement of components against the GIF- or animated engineering files. Subsequently, the assembled wire harnesses on the reusable build plate are verified in real time. Therefore, this invention provides a method that reduces assembly errors by providing precise visual guidance through GIF-based animation. Rapid conversion of engineering drawings into an animated format improves workflow efficiency. Reduced manual intervention during assembly results in consistent manufacturing output. Reference will now be made to… Figure 1 and Figure 2 This invention is described in detail. The embodiments described do not limit the scope and range of this disclosure.

[0032] Figure 1 A block diagram illustrating the modular operation of a method for manufacturing wire harnesses is shown. Figure 1 As shown, the drawing creation module 102 creates a 1:1 scale engineering drawing of the wire harness. Such a drawing can include various components of the wire harness and measurement results.

[0033] The format conversion module 104 converts a 1:1 scale engineering drawing into one or more GIF- or animation-based engineering files 106. The format conversion module 104 is operatively linked to the drawing creation module 102. GIF- or animation-based engineering files are visual representations that use consecutive images or frames to convey step-by-step instructions in a dynamic and interactive manner. Operators will be able to understand the steps required in the fabrication of the wire harness by viewing the GIF- or animation-based engineering files 106.

[0034] The file management module 108 can store, manage, and distribute GIF- or animation-based engineering files 106 across multiple manufacturing units. Manufacturing units can be located in different locations or within the same manufacturing facility. The file management module 108 integrates with Product Lifecycle Management (PLM) or Product Data Management (PDM) software / systems. Here, PLM refers to a strategic approach that manages product data, processing, and information throughout the product's entire lifecycle (from conception to disposal). Here, PDM refers to a method for organizing, storing, and managing product-related data and design documents throughout the development and manufacturing process.

[0035] The converted GIF- or animation-based engineering file 106 is displayed on a reusable build board 112 via a projection setup module 110. The projection setup module 110 includes a computer system 110a and a projector 110b. The computer system 110a may be equipped with software designed to convert engineering drawings into animation-based formats and manage their visual display. The projector 110b may be operatively connected to the computer system 110a and configured to project the converted drawings onto the reusable build board within the manufacturing environment. The reusable build board 112 guides the assembly process for manufacturing wire harnesses.

[0036] A reusable build plate 112 is connected to a component assembly module 114, which is equipped with multiple magnetic or adhesive clamps. These clamps connect to various components of the wire harness. The component assembly module 114 secures the wire harness components according to instructions provided by a converted GIF or animated project file 106.

[0037] After the component assembly module 114 completes the assembly of the wire harness, the quality inspection module 116 verifies the accuracy of the component placement by comparing it with the converted GIF or animation-based project file 106.

[0038] After verification, the onboard test module 118 performs real-time verification of the wiring harnesses assembled on the reusable build board 112.

[0039] In this implementation, projection instructions can be generated by the projection setting module 110. These instructions are transmitted from the central server 122 to the customer MES (Manufacturing Execution System) server 124, and then to multiple MES terminals 124, providing step-by-step visual assistance to guide operators in the precise assembly of the wire harness. This allows operators to easily understand and monitor the various steps involved in manufacturing the wire harness.

[0040] In this implementation, the central server 122 acts as the main control unit for the data flow between the management document management module 108 and the projection setting module 110. The central server 122 can be responsible for storing engineering drawings, converted projection files, and related manufacturing instructions. The central server 122 coordinates the seamless transmission of data to the customer MES server 124, ensuring that all projection instructions are delivered rapidly to maintain the smooth operation of the entire manufacturing facility.

[0041] In this implementation, the customer MES server 124 acts as an intermediate data processor, receiving projection instructions from the central server 122 and distributing them to MES terminals 126 located throughout the wire harness manufacturing facility. The MES terminals 126 display these instructions in real time, providing operators with precise guidance for wire harness assembly. This helps streamline workflows and minimize the need for manual intervention during assembly processes.

[0042] In this implementation, a laser projector is integrated into projector 110b to provide high-precision image projection and alignment capabilities. Projector 110b significantly improves the accuracy of projecting component placement guidelines onto the build plate, thereby enabling more precise assembly.

[0043] In this implementation, computer system 110a can be operatively linked to both central server 122 and projection setup module 110. Computer system 110a can be equipped with software capable of handling various file formats such as .dwg, .dxf, and .drw, thereby providing flexibility and compatibility when processing different types of manufacturing instructions.

[0044] In this implementation, the GIF- or animation-based engineering file 106 may contain manufacturing animations and work instructions. Such manufacturing animations and work instructions can provide the operator with guidance on the steps involved in manufacturing the wire harness.

[0045] In an implementation, the file management module 108 may use a secure data transmission protocol to maintain the integrity and confidentiality of the GIF- or animation-based project file 106 during transmission to the projection setting module 110, the central server 122, the MES server 124, and the MES terminal 126.

[0046] In one implementation, the file management module 108 is configured to synchronize any modifications to the converted GIF- or animation-based engineering file 106 to multiple manufacturing units in real time.

[0047] In one implementation, laser-guided alignment is integrated into the projection setup module 110 to precisely align the projected image onto the reusable build plate 112.

[0048] In this implementation, an interface is provided that allows the operator to interact with the animated projection. The operator can use the projection settings module 110 to pause, rewind, or fast-forward the projection according to the assembly speed.

[0049] In one implementation, the reusable build board 112 is configured to be dynamically adjusted by the component assembly module 114 to accommodate various wiring harness designs.

[0050] In this implementation, multiple operators can perform assembly tasks simultaneously.

[0051] In this implementation, the quality inspection module 116 is configured to provide real-time alerts and feedback to the operator.

[0052] In this implementation, the quality inspection module 116 is configured to capture and record the assembly process for subsequent analysis and quality inspection.

[0053] In this implementation, the onboard test module 118 is configured to perform multiple diagnostic tests.

[0054] In one implementation, the onboard test module 118 is configured to initiate the final assembly of the wiring harness after successfully verifying the test results.

[0055] Figure 2 The process flow associated with the steps of manufacturing wire harnesses is shown. For example... Figure 2 As shown, in step 202, a 1:1 scale engineering parametric drawing can be created using a (Computer-Aided Design) CAD tool (such as CREO Parametric), tailored for precise manufacturing requirements. In step 204, the drawing created in step 201 can be quickly converted into a GIF- or animation-based format to enhance visual clarity and provide step-by-step assembly guidance. In step 206, the converted file can be uploaded to Safety Product Lifecycle Management (PLM) or Product Data Management (PDM) for efficient real-time distribution across different manufacturing facilities. In step 208, a high-precision projector projects GIF-based instructions onto a reusable build board, facilitating rapid setup and accurate component placement. In step 210, in the final manufacturing stage, improved wiring harness assembly precision and reduced manual intervention ultimately enhance production speed, accuracy, and consistency.

[0056] The methods, systems, apparatuses, diagrams, and / or tables discussed herein are examples. Various implementations may appropriately omit, substitute, or add various processes or components. For example, in alternative implementations, the methods may be performed in a different order than described, and / or various stages may be added, omitted, and / or combined. Furthermore, features described with respect to certain implementations may be combined in various other implementations. Different aspects and elements of implementations may be combined in a similar manner. Moreover, technology is constantly evolving, and therefore many of the elements are examples and do not limit the scope of this disclosure or the claims. Additionally, the techniques discussed herein can provide different results through different types of context-aware classifiers.

[0057] Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly or conventionally understood. As used herein, the articles “a” and “an” refer to one or more of the grammatical objects of the article (i.e., at least one). By way of example, “an element” refers to one or more elements. As used herein with respect to measurable values ​​such as quantities, durations of time, etc., “about” and / or “approximately” cover a change of +20% or +10%, +5% or +0.1% compared to the specified value, as such a change is appropriate in the context of the systems, devices, circuits, methods, and other implementations described herein. As used herein with respect to measurable values ​​such as quantities, durations of time, physical properties (such as frequency), “substantially” also covers a change of ±20% or ±10%, ±5% or 0.1% compared to the specified value, as such a change is appropriate in the context of the systems, devices, circuits, methods, and other implementations described herein.

[0058] As used herein, including in the claims, the use of "and" in a list of items beginning with "at least one of..." or "one or more of..." indicates that any combination of the listed items may be used. For example, a list of "at least one of A, B, and C" includes combinations of A or B or C, or AB or AC or BC, and / or any combination of ABC (i.e., A and B and C). Furthermore, where items A, B, or C may appear or be used more than once, multiple uses of A, B, and / or C may form part of the intended combination. For example, a list of "at least one of A, B, and C" may also include AA, AAB, AAA, BB, etc.

[0059] While exemplary and currently preferred embodiments of the disclosed systems, methods, and / or machine-readable media have been described in detail herein, it should be understood that the inventive concept can be implemented and employed in other different ways, and the appended claims are intended to be construed as including such variations, unless limited by the prior art. Although the principles of this disclosure have been described above in conjunction with specific apparatuses and methods, it should be understood that this description is by way of example only and is not intended to limit the scope of this disclosure.

Claims

1. A method for manufacturing a wire harness, the method comprising the following steps: The drawing creation module (102) generates 1:1 scale engineering drawings of the wire harness; The format conversion module (104), which is operatively linked to the drawing creation module (102), converts the engineering drawing into one or more GIF- or animation-based engineering files (106) for enhanced visual guidance; The file management module (108), which is integrated with product lifecycle management (PLM) or product data management (PDM), stores, manages, and distributes the converted GIF or animation-based engineering files (106) to multiple manufacturing units; The converted GIF- or animation-based engineering file (106) is displayed on a reusable build board (112) by a projection setup module (110) including a computer system (110a) and a projector (110b) to guide the assembly process; The component assembly module (114) includes the reusable build plate (112) equipped with multiple adsorption or magnetic clamps, and guides the wire harness component according to the converted GIF or animation-based engineering file (106). The accuracy of component placement is verified by a quality inspection module (116) integrated with multiple sensors against the converted GIF or animation-based engineering file (106); as well as The wiring harness assembled on the reusable building board (112) is verified in real time by the onboard test module (118).

2. The method according to claim 1, wherein, The method further includes embedding manufacturing animations and job instructions within the converted GIF or animation-based project file (106).

3. The method according to claim 1, wherein, The method further includes employing a secure data transmission protocol to maintain the integrity and confidentiality of the converted GIF- or animation-based project file (106) during transmission using the file management module (108).

4. The method according to claim 1, wherein, The method further includes using the file management module (108) to synchronize any modifications to the converted GIF or animation-based engineering file (106) to the plurality of manufacturing units in real time.

5. The method according to claim 1, wherein, The method further includes reading and displaying various file formats via the computer system (110a) operably connected to the projector (110b) to project the converted GIF- or animation-based project file (106) onto the reusable build board (112) using the projection settings module (110).

6. The method according to claim 1, wherein, The method further includes: using laser-guided alignment integrated in the projection setting module (110) to precisely align the projected image onto the reusable building board (112).

7. The method according to claim 1, wherein, The method also includes interacting with the animation projection via an interface that allows the operator to pause, rewind, or fast forward the animation projection according to the assembly speed using the projection settings module (110).

8. The method according to claim 1, wherein, The method also includes dynamically adjusting the reusable building block (112) via the component assembly module (114) to adapt to various wiring harness designs.

9. The method according to claim 1, wherein, The method also includes allowing multiple operators to perform assembly tasks simultaneously.

10. The method according to claim 1, wherein, The method also includes providing real-time alerts and feedback to the operator via the quality control module.

11. The method according to claim 1, wherein, The method further includes capturing and recording the assembly process via the quality inspection module (116) for subsequent analysis and quality inspection.

12. The method according to claim 1, wherein, The method also includes performing multiple diagnostic tests via the onboard test module (118).

13. The method according to claim 1, wherein, The method further includes: after successfully verifying the test results using the onboard test module (118), starting the final assembly of the wiring harness.

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