Rotary wire bundle dispensing device

Abstract

The present disclosure provides a "rotary wire harness dispensing device". A system for installing a wire harness into a vehicle, the system comprising a spool, at least one robot, and a controller. The spool is configured to support the wire harness and comprises a first retention feature configured to couple a first connector of the wire harness to the spool. The robot is coupled to the spool and is configured to move the spool. The controller is in communication with the robot and is configured to: command the robot to connect the first connector to a first module of the vehicle, and command the robot to disconnect the first connector from the first retention feature.

Description

Technical Field

[0001] This disclosure relates to a rotary wire harness distribution device. 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 the lack of proper manipulation of parts and mechanical repeatability.

[0004] This disclosure resolves these problems related to automated manipulation components, as well as other problems related to processing 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 embodiment, this disclosure provides a system for mounting a wiring harness into a vehicle, the system including a reel, at least one robot, and a controller. The reel is configured to support the wiring harness and includes a first retaining feature configured to engage a first connector of the wiring harness to the reel. The robot is engaged with the reel and configured to move the reel. The controller communicates with the robot and is configured to: command the robot to connect the first connector to a first module of the vehicle, and command the robot to disconnect the first connector from the first retaining feature.

[0007] In a variation of the system described in the previous paragraph, which can be implemented individually or in any combination: the robot connects the first connector to the first module and simultaneously disconnects the first connector from the first retaining feature; the reel includes a body, a first flange, and a second flange opposite to the first flange, the first retaining feature being coupled to the first flange; the robot is coupled to the body of the reel; the reel includes a second retaining feature spaced apart from the first retaining feature, the second retaining feature being configured to couple a second connector of the wiring harness to the reel; each of the first and second retaining features includes a clamp or hook-and-loop fastener; the controller is configured to: command the robot to connect the second connector to a second module of the vehicle after the first connector is connected to the first module; and command the robot to disconnect the second connector from the second retaining feature, the second module being spaced apart from the first module; the second retaining feature being coupled to the first flange; the second retaining feature being coupled to the second flange; and the robot connecting the second connector to the second module and simultaneously disconnecting the second connector from the second retaining feature.

[0008] In another form, this disclosure provides a system for mounting a wiring harness into a vehicle, the system including a reel, at least one robot, and a controller. The reel is configured to support the wiring harness and includes a plurality of retaining features. A first retaining feature of the plurality of retaining features is configured to engage a first connector of the wiring harness to the reel, and a second retaining feature of the plurality of retaining features is configured to engage a second connector of the wiring harness to the reel. The robot is engaged with the reel and configured to move the reel. The controller communicates with the robot and is configured to: command the robot to connect the first connector to a first module located at a first position in the vehicle; command the robot to disconnect the first connector from the first retaining feature; command the robot to move the reel to a second position in the vehicle after the first connector has been connected to the first module to connect the second connector to a second module in the vehicle; and command the robot to disconnect the second connector from the second retaining feature, wherein, in response to the robot moving the reel from the first position toward the second position, the wiring harness is at least partially unwound from the reel.

[0009] In a variation of the system described in the previous paragraph, which can be implemented individually or in any combination: the robot connects the first connector to the first module and simultaneously disconnects the first connector from the first retaining feature; the robot connects the second connector to the second module and simultaneously disconnects the second connector from the second retaining feature; each of the plurality of retaining features includes a clamp or hook-and-loop fastener; the reel includes a first flange and a second flange opposite to the first flange, the first retaining feature and the second retaining feature being coupled to the periphery of the first flange; the plurality of retaining features includes a third retaining feature configured to engage a third connector of the harness to the reel, and wherein the controller is configured to: command the robot to move from the second position to the vehicle after the second connector is connected to the second module. The robot is positioned at a third position to connect the third connector to a third module of the vehicle, and is commanded to disconnect the third connector from the third retaining feature. In response to the robot moving the reel from the second position toward the third position, the wiring harness is further unwound on the reel. The third retaining feature is coupled to the periphery of the first flange. The third retaining feature is coupled to the periphery of the second flange. The robot includes a first robot and a second robot, the first robot being configured to move the reel from the first position to the second position, and the second robot being configured to disconnect the first connector from the first retaining feature and connect the first connector to the first module of the vehicle, and to disconnect the second connector from the second retaining feature and connect the second connector to the second module of the vehicle.

[0010] In another embodiment, this disclosure provides a system for mounting a wiring harness to a vehicle, the system including a spool, the wiring harness, at least one robot, and a controller. The spool includes a first flange, a second flange opposite the first flange, and a plurality of retaining features coupled to at least one of the first flange and the second flange. The wiring harness is wound around the spool and includes a plurality of connectors. Each of the plurality of retaining features is configured to engage a corresponding connector of the plurality of connectors to the spool. The robot is coupled to the spool and configured to move the spool. The controller communicates with the robot and is configured to: command the robot to connect a first connector of the plurality of connectors to a first module located at a first position in the vehicle; command the robot to disconnect the first connector from the first retaining feature of the plurality of retaining features; command the robot to move the spool to a second position in the vehicle after the first connector is connected to the first module to connect a second connector of the plurality of connectors to a second module in the vehicle; and command the robot to disconnect the second connector from the second retaining feature of the plurality of retaining features. In response to the robot moving the spool from the first position toward the second position, the wire harness is at least partially unwound on the spool.

[0011] In a variation of the system described above, the robot includes a first robot and a second robot. The first robot is configured to move the reel from a first position to a second position. The second robot is configured to disconnect the first connector from the first retaining feature and connect the first connector to the first module of the vehicle, and to disconnect the second connector from the second retaining feature and connect the second connector to the second module 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: Figure 1 It is a perspective view of a system for manipulating a vehicle wiring harness component according to the principles of this disclosure, wherein the wiring harness component is wound on a spool of the system. Figure 2A It is connected to Figure 1 The system's reel Figure 1 A perspective view of the robot system; Figure 2B It is a perspective view of a scroll; Figure 3A yes Figure 1 A side view of the reel, with the wire harness component removed for clarity; Figure 3B yes Figure 1 The end view of the reel, with the wire harness component removed for clarity; Figure 3C and Figure 3D It can be combined with Figure 1 Perspective view of alternative retaining features in the scroll; Figures 4A to 4C This is a schematic diagram showing the robot connecting an electrical connector to a module in the vehicle; Figure 5 It is shown that, in accordance with the teachings of this disclosure Figure 1 A schematic block diagram of the system components; and Figure 6 It describes the manipulation based on the teachings of this disclosure. Figure 1 The flowchart of the algorithm for the wiring harness component of the system; Figure 7A This is a perspective view of another system of wiring harness components for manipulating a vehicle, based on the principles of this disclosure. Figure 7B yes Figure 7A A perspective view of a part of the robot system; Figure 8 It is shown that, in accordance with the teachings of this disclosure Figure 7A A schematic block diagram of the system components; and Figure 9 It describes the manipulation based on the teachings of this disclosure. Figure 7A The flowchart of the algorithm for the wiring harness component of the system; 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

[0014] 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.

[0015] refer to Figure 1 The diagram illustrates a system 10 for manipulating one or more vehicle components 12. Manipulation of the vehicle component 12 may include retrieving the vehicle component 12 from a part support (e.g., a rack), placing the vehicle component 12 onto a work surface, manipulating parts of the vehicle component 12 on the work surface, and / or mounting the vehicle component 12 onto a vehicle 17 (e.g., Figures 4A to 4CSystem 10 allows for the manipulation of vehicle component 12 with minimal human intervention. In this way, the manipulation of vehicle component 12 can be automated to, for example, increase productivity, reduce cycle time, and minimize variability and error. In the example shown, vehicle component 12 may include a wiring harness. 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 vehicle 17 potentially difficult to automate. System 10 of this disclosure provides adaptation to vehicle components 12, such as wiring harnesses, to better support automation. It should be understood that vehicle component 12 may be other components of the vehicle besides wiring harnesses.

[0016] refer to Figure 1 Figure 2 Figures 3A to 3B The system 10 includes at least one robot 14, a reel 16, and a vehicle component 12. Figure 1 (and Figure 2) and controller 20 ( Figure 5 Robot 14 is configured to move reel 16 and vehicle component 12 from, for example, a work surface (not shown) to vehicle 17, connect the electrical connector 21a of vehicle component 12 to vehicle module 18 of vehicle 17, and disconnect or detach the electrical connector 21a of vehicle component 12 from reel 16. Robot 14 includes a robot arm 14a and a robot gripper structure or device 14b. Robot arm 14a includes multiple segments connected to each other at joints, thereby allowing robot 14 to have multiple degrees of freedom. In one form, robot arm 14a is fixed to a work surface at a first end. In some variations, robot arm 14a includes an optional adapter (not shown) adapted to be fixed to a work surface. In some forms, robot 14 is detached from the work surface and is partially or fully autonomous, and is configured to autonomously move to a part support (not shown) and / or work surface as commanded by controller 20. To move itself autonomously, controller 20 is configured to control various movement systems of robot 14 based on position data obtained from one or more sensors. In an exemplary application, the mobile system may include a propulsion system, a steering system for controlling the wheels, and / or other systems, and the sensors used to provide location data may include GNSS sensors, imaging sensors, local location sensors, etc.

[0017] A robotic gripper structure 14b is attached to the robotic arm 14a and configured to be removably coupled to the reel 16. In this way, the robotic gripper structure 14b can grip the reel 16 and move it from one position to another, as will be described in more detail below. In the example shown, the robotic gripper structure 14b is coupled to the reel 16. In some forms, the robotic gripper structure 14b can be coupled to the periphery of the reel 16 or any other suitable location on the reel 16, allowing the robot 14 to move the reel 16. The robotic gripper structure 14b can also manipulate the reel 16 (e.g., rotate the reel 16) to connect the electrical connector 21a of the vehicle component 12 to the terminals of the vehicle module 18, as will be described in more detail below. In one example, the vehicle module 18 may be an engine control module that controls multiple systems of an internal combustion engine. In another example, the vehicle module 18 may be a suspension module that controls the suspension and independently adjusts the tension of each wheel. It should be understood that the module may be another module configured to control the operation of the vehicle 17 and its systems.

[0018] The spool 16 is configured to support the wire harness 12 and includes a body 22. Figure 3A The body 22 comprises flanges 24a and 24b and multiple retaining features 26a and 26b. The body 22 and flanges 24a and 24b cooperate to form a space for winding the wire harness 12. In the example shown, the body 22 has a cylindrical shape. In some forms, the body 22 may have different shapes, such as elliptical. In one form, the body 22 is hollow. In another form, the body 22 is solid. In the example shown, the body 22 has an axial end 28 (only one shown in the figure) that includes multiple mounting features 34. The mounting features 34 may be a combination of slots, holes, and / or grooves. In one form, the mounting features 34 facilitate the attachment of the robot 14 to the reel 16. That is, the robot gripper structure 14b can be attached to the body 22 via the mounting features 34 to removably attach the robot 14 to the reel 16. In another form, the mounting features 34 reduce the weight of the reel 16. In another form, mounting feature 34 facilitates the attachment of retaining features 26a, 26b to reel 16. In this form, mounting feature 34 may be arranged in a pattern to facilitate the attachment of retaining features 26a, 26b to body 22.

[0019] Each flange 24a, 24b extends radially outward from the corresponding axial end 28 of the body 22 and can be configured to inhibit movement of the wire harness 12 in the axial direction (i.e., along the length of the body 22 of the reel 16). The flanges 24a, 24b may include a plurality of mounting features 36 ( Figure 2A and Figure 2BMounting feature 36 can be a combination of slots, holes, and / or recesses. In one form, mounting feature 36 reduces the weight of reel 16. In yet another form, mounting feature 36 facilitates the attachment of retaining features 26a, 26b to reel 16, as will be described in more detail below. In this form, mounting feature 36 can be patterned to facilitate the attachment of retaining features 26a, 26b to reel 16 and the disengagement of electrical connector 21a from reel 16. In yet another form, mounting feature 36 can facilitate the attachment of electrical components 21 (e.g., wires) of wire harness 12 to reel 16. In this way, wire harness 12 is further supported on reel 16 as it moves from one position to another. In some forms, mounting feature 36 can facilitate the attachment of robot 14 to reel 16. In other words, the robot gripper structure 14b can be connected to the flanges 24a, 24b via the mounting feature 36 to removably connect the robot 14 to the reel 16.

[0020] Refer to Figure 2. Figure 3A and Figure 3B The retaining features 26a and 26b are respectively connected to the flanges 24a and 24b of the reel 16 and are configured to support the electrical connector 21a of the wire harness 12 on the reel 16. In some forms, the retaining features 26a and 26b may be connected to the flange 24a instead of the flange 24b. Furthermore, in other forms, the retaining features 26a and 26b may be connected to the axial end 28 of the body 22 to support the electrical connector 21a of the wire harness 12 on the body 22 of the reel 16.

[0021] Retaining features 26a and 26b are removably attached to flanges 24a and 24b, respectively, and are spaced apart from each other along flanges 24a and 24b. In the example shown, retaining features 26a and 26b are attached to flanges 24a and 24b via mechanical fasteners (such as bolts, screws, or rivets), such as mounting features 36 extending through flanges 24a and 24b. In this way, the pattern of retaining features 26a and 26b arranged along reel 16 can be changed, modified, or updated as needed. In some forms, retaining features 26a and 26b can be attached to flanges 24a and 24b using a snap-on system, hook-and-loop fasteners (VELCRO), or any other suitable attachment mechanism, wherein the pattern of retaining features 26a and 26b arranged along reel can be updated as needed.

[0022] Features 26a and 26b are configured to removably attach electrical connector 21a to reel 16 using various attachment methods. Figure 3A Figure 3BIn the example shown, each retaining feature 26a, 26b is coupled to a corresponding flange 24a, 24b and includes a space 48 formed by the walls 50 of the retaining features 26a, 26b, which receives a corresponding electrical connector 21a. In this way, as the robot 14 moves the reel 16, the corresponding electrical connector 21a is engaged with the retaining features 26a, 26b. The two walls 50 may include flanges 55 extending above the electrical connector 21a to further retain the electrical connector 21a to the retaining features 26a, 26b. In another example, as... Figure 3C As shown, retaining feature 26c can be coupled to corresponding flanges 24a, 24b, and includes a hook-and-loop fastener system 60 connected to the corresponding electrical connector 21a. That is, one of the retaining feature 26c and the corresponding electrical connector 21a includes a hook that engages with a loop of the other, thereby coupling the corresponding electrical connector 21a of the wire harness 12 to the reel 16. Figure 3D In yet another example shown, the retaining feature 26d includes a space formed by a resilient flexible wall 62 of the retaining feature 26d, the space receiving a corresponding electrical connector 21a. In this way, for example, when the robot 14 moves the reel 16, the corresponding electrical connector 21a is held to the retaining feature 26d by frictional engagement. It should be understood that, without departing from the scope of this disclosure, the reel 16 may include combinations of the retaining features 26a, 26b, 26c, and 26d disclosed above.

[0023] The wire harness 12 is wound around the body 22 of the spool 16, such that the spool 16 supports the wire harness 12. As described above, when the robot 14 moves the spool 16, the electrical connector 21a of the wire harness 12 engages with the retaining features 26a, 26b. As will be described in more detail below, when the robot 14 connects the electrical connector 21a to the vehicle module 18, the wire harness 12 is unwound from the spool 16.

[0024] refer to Figure 5 The controller 20 communicates with the robot 14 and can monitor and control the operation of the robot 14 based on the received data. In one example, the controller 20 communicates with the robot 14 using wired or wireless communication protocols (e.g., Bluetooth®, cellular, Wi-Fi, Near Field Communication (NFC), Ultra Wideband (UWB), etc.).

[0025] refer to Figure 6An exemplary control algorithm 200 for mounting a wiring harness 12 into a vehicle 17 is shown. Once the wiring harness 12 has moved from a part support (not shown) to a work surface or the area where the robot 14 is located, processing can begin. At 204, the control algorithm uses the controller 20 to command the robot 14 to clamp the spool 16 on which the wiring harness 12 is wound. At 208, the control algorithm uses the controller 20 to command the robot 14 to connect the first electrical connector 21a of the spool 16 to the corresponding vehicle module 18 of the vehicle 17. Figure 4A In the example shown, the corresponding module 18 is located at the front 70 of the vehicle 17. In another form, the corresponding module 18 may be located at the rear 74 of the vehicle 17. In yet another form, the corresponding module 18 may be located at the middle portion 72 of the vehicle 18 or at any other location on the vehicle 17 that includes the vehicle module. It should be understood that the robot 14 may manipulate the reel 16 (e.g., rotate the reel 16) such that the first electrical connector 21a is connected to the corresponding module 18.

[0026] At 212, the control algorithm uses controller 20 to command robot 14 to disconnect or separate the first electrical connector 21a from the reel 16 (i.e., to separate the first electrical connector 21a from the corresponding retaining features 26a, 26b of the reel 16). For example, after the first electrical connector 21a has been connected to the corresponding module 18, robot 14 can move the reel 16 away from the corresponding module 18, thereby disconnecting the first electrical connector 21a from the retaining features 26a, 26b of the reel 16. In other words, once a predetermined force is applied to the reel 16, the connection between the first electrical connector 21a and the retaining features 26a, 26b can be overcome, thereby disconnecting the first electrical connector 21a from the retaining features 26a, 26b. In some forms, the movement of robot 14 to connect the first electrical connector 21a to the corresponding module 18 and to disconnect the first electrical connector 21a from the retaining features 26a, 26b can occur simultaneously.

[0027] At 216, the control algorithm uses controller 20 to command robot 14 to move reel 16 to a second position on vehicle 17 and connect second electrical connector 21a to another vehicle module 18. In the example shown, the second position of vehicle 17 could be the middle section of vehicle 17. Figure 4B In some forms, the second position of vehicle 17 may be the rear of vehicle 17 or another position of vehicle 17 spaced apart from the front of vehicle 17. It should be understood that, in response to robot 14 moving from the first position to the second position, harness 12 may be at least partially unwound on reel 16.

[0028] At 220, the control algorithm uses the controller 20 to command the robot 14 to disconnect or separate the second electrical connector 21a from the reel 16 (i.e., to separate the second electrical connector 21a from the corresponding retaining features 26a, 26b of the reel 16). For example, after the second electrical connector 21a has been connected to the corresponding module 18, the robot 14 can move the reel 16 away from the corresponding module 18, thereby disconnecting the second electrical connector 21a from the retaining features 26a, 26b of the reel 16. In other words, once a predetermined force is applied to the reel 16, the connection between the second electrical connector 21a and the retaining features 26a, 26b can be overcome, thereby disconnecting the second electrical connector 21a from the retaining features 26a, 26b. In some forms, the movement of the robot 14 to connect the second electrical connector 21a to the corresponding module 18 and to disconnect the second electrical connector 21a from the retaining features 26a, 26b can occur simultaneously.

[0029] The controller 20 can command the robot 14 to connect all electrical connectors 21a of the wiring harness 12 to the vehicle module 18 one at a time, thereby unwinding the wiring harness 12 from the reel 16 and installing it into the vehicle 17. The electrical connectors 21a can be connected to the vehicle module 18 in a predetermined sequence and disconnected from the retaining feature 26 to further suppress tangling of the wiring harness 12. For example, the controller 20 commands the robot 14 to connect adjacent electrical connectors 21a to the vehicle 17 to suppress tangling of the wiring harness 12 during installation. The system 10 of this disclosure provides the benefit of suppressing tangling of the reel 16 and the wiring harness 12 during transport and allows the reel 16 to be reused after the wiring harness 12 has been installed into the vehicle 17. The system 10 also allows for automated installation of the wiring harness 12 into the vehicle 17.

[0030] refer to Figure 7A , Figure 7B , Figure 8 and Figure 9 This illustrates another system 310 for manipulating one or more wire harnesses 312. Apart from the differences mentioned below, the structure and function of system 310 may be similar to or the same as system 10 described above.

[0031] System 310 includes robots 314a and 314b, a reel 316, and a controller 320. Figure 8 Robot 314a is configured to move the reel 316 and vehicle component 312 from a work surface (not shown), for example, to vehicle 17 and along the length of vehicle 17. Robot 314a includes a robot arm 324a and a robot gripper structure or device 324b. The structure and function of robot 314a may be similar to or the same as those of robot 14 described above, and therefore will not be described in detail.

[0032] Robot 314b is configured to connect the electrical connector 321a of wiring harness 312 to vehicle module 18 of vehicle 17 and to disconnect or detach the electrical connector 321a of wiring harness 312 from reel 316. Robot 314b includes a robot arm 340 and a robot gripper structure or device 380. Robot arm 340 includes multiple segments connected to each other at joints, thereby allowing robot 314b to have multiple degrees of freedom. Robot arm 340 may be fixed to a work surface at a first end. In some variations, robot arm 340 includes an optional adapter (not shown) suitable for fixing to the work surface. In some forms, robot 314b is detached from the work surface and is partially or fully autonomous, and is configured to autonomously move to a part support (not shown) and / or work surface as commanded by controller 320. To move itself autonomously, controller 320 is configured to control various movement systems of robot 314b based on position data obtained from one or more sensors. In an exemplary application, the mobile system may include a propulsion system, a steering system for controlling the wheels, and / or other systems, and the sensors used to provide location data may include GNSS sensors, imaging sensors, local location sensors, etc.

[0033] The robot gripper structure 380 is attached to the robot arm 340 and configured to grip and move the electrical connector 321a of the wire harness 312 from the reel 316. The robot gripper structure 380 is also configured to connect the electrical connector 321a to the vehicle module 18, as will be described in more detail below.

[0034] refer to Figure 7B The robot gripper structure 380 includes an actuator assembly 388 and a pair of opposing grippers 390. The actuator assembly is fixed to the second end of the robot arm 340. The actuator assembly 388 includes a body 392 and a motor 393. Figure 8A robot arm 340 consists of a main body 392 and a pair of movable components or arms 394. The main body 392 is fixed to the second end of the robot arm 340. A motor 393 is associated with the main body 392 (e.g., disposed within the main body 392) and is electrically in communication with a controller 320. The controller 320 may communicate with the motor 393 via, for example, the Internet, Wi-Fi, Bluetooth®, Zigbee®, power line carrier communication (PLCC), or a cellular connection, or any other wired or wireless communication protocol. The motor 393 can operate between a closed mode and an open mode. In one form, the motor 393 may be an electric motor, such as a brushless drive motor. Each arm 394 is operatively connected to the motor 393 via a corresponding guide rail or connecting member (not shown) and is permitted to move in the lateral direction (i.e., laterally than the longitudinal direction of the arm 394). For example, when the motor 393 is in the closed mode, the arm 394 is prohibited from moving in the lateral direction. When the motor 393 is in the open mode, the arm 394 is permitted to move in the lateral direction between an open state and a closed state.

[0035] Each gripper 390 is secured to a corresponding arm 394 and is movable in the lateral direction between a first or closed position and a second or open position. In other words, each gripper 390 is secured to a corresponding arm 394 such that when the corresponding arm 394 is in the closed position, the gripper 390 is in the closed position, and when the corresponding arm 394 is in the open position, the gripper 390 is in the open position. When the gripper 390 is in the closed position, the gripper 390 can grasp and move the electrical connector 321a. When the gripper 390 is in the open position, the gripper 390 can disengage from the electrical connector 321a. An example of such a pair of grippers is disclosed in U.S. Patent Application No. XX / 000,000, entitled “SYSTEM FOR HANDLING ELECTRICAL COMPONENTS,” which is jointly owned with this application, and the contents of which are incorporated herein by reference in their entirety.

[0036] Reel 316 is configured to support wire harness 312. The structure and function of reel 316 may be similar to or the same as those of reel 16 described above, and therefore will not be described in detail further. (See reference...) Figure 8 The controller 320 communicates with robots 314a and 314b and can monitor and control the operation of robots 314a and 314b based on the received data. In one example, the controller 320 communicates with robots 314a and 314b using wired or wireless communication protocols (e.g., Bluetooth®, cellular, Wi-Fi, Near Field Communication (NFC), Ultra Wideband (UWB), etc.).

[0037] refer to Figure 9 An exemplary control algorithm 400 for mounting the wiring harness 312 into the vehicle 17 is shown. Processing can begin once the wiring harness 312 has moved from the part support (not shown) to the work surface or the area where the robots 314a, 314b are located. At 404, the control algorithm uses the controller 320 to command the robot 314a to clamp the spool 316 on which the wiring harness 312 is wound and to move it toward the spool 316. At 408, the control algorithm uses the controller 320 to command the robot 314b to disconnect or separate the first electrical connector 321a from the spool 316 (i.e., to separate the first electrical connector 321a from the corresponding retaining feature of the spool 316).

[0038] At 412, the control algorithm uses controller 320 to command robot 314b to connect the first electrical connector 321a to the corresponding vehicle module 18. In the example shown, the corresponding module 18 is located at the front of vehicle 17. In another form, the corresponding module 18 may be located at the rear of vehicle 17. In yet another form, the corresponding module 18 may be located in the middle of vehicle 18 or at any other location on vehicle 17 that includes the vehicle module.

[0039] At 416, the control algorithm uses controller 320 to command robot 314a to move reel 316 to vehicle. 17 The second position is spaced apart from the first position of vehicle 17. In the example shown, the second position of vehicle 17 may be the middle portion of vehicle 17. In some forms, the second position of vehicle 17 may be the rear portion of vehicle 17 or another position of vehicle 17 spaced apart from the front portion of vehicle 17. It should be understood that in response to robot 314a moving from the first position to the second position, the wire harness 312 may be at least partially unwound on the reel 316.

[0040] At 420, the control algorithm uses controller 320 to command robot 314b to disconnect or separate the second electrical connector 321a from spool 316 (i.e., to separate the second electrical connector 321a from the corresponding retaining feature of spool 316). At 424, the control algorithm uses controller 320 to command robot 314b to connect the second electrical connector 321a to another vehicle module 18 of vehicle 17. Controller 320 can command robot 314a to move along vehicle 17 and command robot 314b to connect all electrical connectors 321a of wiring harness 312 to vehicle module 18 one at a time, such that wiring harness 312 is unwound from spool 316 and installed into vehicle 17.

[0041] 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.

[0042] As used herein, the phrases A, B, and C at least one should be interpreted as representing logic (A or B or C) using the non-exclusive logic "or", and should not be interpreted as representing "at least one of A, at least one of B, and at least one of C".

[0043] 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; or combinations of some or all of the foregoing, such as in a system-on-a-chip.

[0044] 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).

[0045] 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.

[0046] The description in this disclosure is merely exemplary in nature, and therefore, variations 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.

[0047] According to the present invention, a system for mounting a wiring harness into a vehicle is provided, the system comprising: a reel configured to support the wiring harness and including a plurality of retaining features, a first retaining feature of the plurality of retaining features being configured to engage a first connector of the wiring harness to the reel, and a second retaining feature of the plurality of retaining features being configured to engage a second connector of the wiring harness to the reel; at least one robot coupled to the reel and configured to move the reel; and a controller communicating with the at least one robot, the controller being configured to: command the at least one robot to connect the first connector to a first module located at a first position in the vehicle; command the at least one robot to disconnect the first connector from the first retaining feature; command the at least one robot to move the reel to a second position in the vehicle after the first connector has been connected to the first module to connect the second connector to a second module in the vehicle; and command the at least one robot to disconnect the second connector from the second retaining feature, wherein in response to the at least one robot moving the reel from the first position toward the second position, the wiring harness is at least partially unwound on the reel.

[0048] According to one embodiment, the at least one robot connects the first connector to the first module and simultaneously disconnects the first connector from the first retaining feature, and wherein the at least one robot connects the second connector to the second module and simultaneously disconnects the second connector from the second retaining feature.

[0049] According to one embodiment, each of the plurality of retaining features includes a clip or hook-and-loop fastener.

[0050] According to one embodiment, the reel includes a first flange and a second flange opposite to the first flange, wherein the first retaining feature and the second retaining feature are coupled to the periphery of the first flange.

[0051] According to one embodiment, the plurality of retaining features includes a third retaining feature configured to engage a third connector of the wiring harness to the reel, and wherein the controller is configured to: command at least one robot to move from a second position to a third position of the vehicle after the second connector is connected to the second module to connect the third connector to a third module of the vehicle; and command at least one robot to disconnect the third connector from the third retaining feature, wherein in response to the at least one robot moving the reel from the second position toward the third position, the wiring harness is further unwound on the reel.

[0052] According to one embodiment, the third retaining feature is coupled to the periphery of the first flange.

[0053] According to one embodiment, the third retaining feature is coupled to the periphery of the second flange.

[0054] According to one embodiment, the at least one robot includes: a first robot configured to move the reel from the first position to the second position; and a second robot configured to disconnect the first connector from the first retaining feature and connect the first connector to the first module of the vehicle, and to disconnect the second connector from the second retaining feature and connect the second connector to the second module of the vehicle.

[0055] According to the present invention, a system for mounting a wire harness into a vehicle is provided, the system comprising: a reel including a first flange, a second flange opposite to the first flange, and a plurality of retaining features coupled to at least one of the first flange and the second flange; the wire harness being wound on the reel and including a plurality of connectors; each of the plurality of retaining features being configured to engage a corresponding connector of the plurality of connectors to the reel; at least one robot coupled to the reel and configured to move the reel; and a controller communicating with the at least one robot, the controller being configured to command the at least one robot to move the plurality of connectors... A first connector in the connectors is connected to a first module located at a first position in the vehicle; the at least one robot is commanded to disconnect the first connector from the first retaining feature in the retaining feature; the at least one robot is commanded to move the reel to a second position in the vehicle after the first connector is connected to the first module to connect a second connector in the plurality of connectors to a second module in the vehicle; and the at least one robot is commanded to disconnect the second connector from the second retaining feature in the plurality of retaining features, wherein in response to the at least one robot moving the reel from the first position toward the second position, the harness is at least partially unwound on the reel.

[0056] According to one embodiment, the at least one robot includes: a first robot configured to move the reel from the first position to the second position; and a second robot configured to disconnect the first connector from the first retaining feature and connect the first connector to the first module of the vehicle, and to disconnect the second connector from the second retaining feature and connect the second connector to the second module of the vehicle.

Claims

1. A system for installing a wiring harness into a vehicle, the system comprising: A reel configured to support the wire harness and including a first retaining feature configured to engage a first connector of the wire harness to the reel; At least one robot, the at least one robot being coupled to the reel and configured to move the reel; and A controller, which communicates with the at least one robot, is configured to: The command instructs at least one robot to connect the first connector to the first module of the vehicle; and The command instructs at least one robot to disconnect the first connector from the first retaining feature.

2. The system of claim 1, wherein the at least one robot connects the first connector to the first module and simultaneously disconnects the first connector from the first retaining feature.

3. The system of claim 1, wherein the reel includes a body, a first flange and a second flange opposite to the first flange, and wherein the first retaining feature is coupled to the first flange.

4. The system of claim 3, wherein the at least one robot is coupled to the body of the reel.

5. The system of claim 3, wherein the reel includes a second retaining feature spaced apart from the first retaining feature, and wherein the second retaining feature is configured to engage a second connector of the wire harness to the reel.

6. The system of claim 5, wherein each of the first retaining feature and the second retaining feature comprises a clip or hook-and-loop fastener.

7. The system of claim 5, wherein the controller is configured to: The command instructs at least one robot to connect the second connector to the second module of the vehicle after the first connector is connected to the first module; and The command instructs at least one robot to disconnect the second connector from the second retaining feature. The second module is spaced apart from the first module.

8. The system of claim 7, wherein the second retaining feature is coupled to the first flange.

9. The system of claim 7, wherein the second retaining feature is coupled to the second flange.

10. The system of claim 7, wherein the at least one robot connects the second connector to the second module and simultaneously disconnects the second connector from the second retaining feature.

11. The system of claim 7, wherein in response to the at least one robot moving the reel from a first position toward a second position, the wire harness is at least partially unwound on the reel.

12. The system of claim 11, further comprising a third retaining feature configured to engage a third connector of the wire harness to the reel, and wherein the controller is configured to: The robot is commanded to move from the second position to a third position on the vehicle after the second connector is connected to the second module, in order to connect the third connector to the third module of the vehicle; and The command instructs at least one robot to disconnect the third connector from the third retaining feature. In response to the at least one robot moving the reel from the second position toward the third position, the wire harness is further unwound on the reel.

13. The system of claim 7, wherein the at least one robot connects the first connector to the first module and simultaneously disconnects the first connector from the first retaining feature, and wherein the at least one robot connects the second connector to the second module and simultaneously disconnects the second connector from the second retaining feature.

14. The system of claim 5, wherein the first retaining feature and the second retaining feature comprise a clip or hook-and-loop fastener.

15. The system of claim 5, wherein the reel includes a first flange and a second flange opposite to the first flange, and wherein the first retaining feature and the second retaining feature are coupled to the periphery of the first flange.

Images