Method and system for the fully automated production of a cable harness

Abstract

Method for the automated production of a cable harness (300), - wherein a vehicle (25), a mold board (30) and a cable storage (35) are provided, - wherein the vehicle (25) is a non-rail land vehicle or an unmanned aerial vehicle, - wherein a first electrical cable (165) is stored in the cable storage (30), - wherein the vehicle (25) is moved to the cable storage (35), - wherein the vehicle (25) receives at least the first electrical cable (165) by means of an insertion device (50), - wherein the vehicle (25) is moved from the cable storage (35) to the forming board (30) and transports the received first electrical cable (165) from the cable storage (35) to the forming board (30), - wherein the vehicle (25) is moved on the forming board (30) along a predefined first movement path (200) and the insertion device (50) inserts the first electrical cable (165) into a cable receptacle (115) of the forming board (30).

Description

[0001] The invention relates to a method for the fully automated production of a cable harness according to patent claim 1 and a system according to patent claim 8.

[0002] Typically, in the manufacture of automotive wiring harnesses, electrical cables are manually pulled along a forming board and inserted into holders. The individual electrical cables are then wrapped to form a wire harness. Therefore, the manufacturing of the wiring harness is very time-consuming and labor-intensive.

[0003] Furthermore, a molded board with a groove-shaped cable receptacle is known from WO 2017 / 194 538 A1.

[0004] Various methods for producing a cable harness are known from US 2001 / 0 019 478 A1, DE 10 2017 206 141 A1, US 9 721 702 B1, EP 0 588 386 A1 and DE 10 2017 206 140 A1.

[0005] It is an object of the invention to provide an improved method and an improved system for the fully automated production of a wiring harness of a motor vehicle.

[0006] This object is achieved by means of a method according to claim 1 and by means of a system according to claim 8. Advantageous embodiments are specified in the dependent claims.

[0007] It has been recognized that an improved method and an improved system can be provided by providing a vehicle, a forming board and a cable storage facility, wherein the vehicle is a non-rail-bound vehicle or an unmanned aerial vehicle, wherein at least a first electrical cable is stored in the cable storage facility, wherein the vehicle is moved to the cable storage facility, wherein the vehicle receives at least the first electrical cable by means of an insertion device, wherein the vehicle is moved from the cable storage facility to the forming board and the received first electrical cable is transported from the cable storage facility to the forming board, wherein the vehicle is moved along the forming board along a predefined first movement path and the insertion device inserts the first electrical cable into at least one cable receptacle of the forming board.

[0008] This design has the advantage that the cable laying can be fully automated and thus the cable harness can be manufactured particularly easily and cost-effectively.

[0009] In a further embodiment, after the first cable has been inserted into the cable receptacle, the insertion device is released from the first electrical cable, and after the first cable has been released, the vehicle is moved back to the cable storage area, wherein the insertion device picks up a second electrical cable from the cable storage area at the cable storage area, wherein the vehicle is moved with the second electrical cable to the forming board, wherein the vehicle is moved along the forming board along a predefined second movement path and, along the second predefined movement path, the insertion device inserts the second electrical cable into at least the cable receptacle of the forming board, wherein the first movement path and the second movement path preferably run identically in sections. As a result, several, possibly different, electrical cables of the wiring harness can be laid cost-effectively using one vehicle.

[0010] In a further embodiment, the insertion device inserts the first electrical cable substantially completely into the cable receptacle, wherein a foam material is introduced into the cable receptacle, wherein the foam material flows around at least the first electrical cable, optionally also the second electrical cable, and encloses it at least partially, preferably completely, wherein the foam material swells and hardens. The foam material can be introduced into the cable receptacle in an automated manner.

[0011] In a further embodiment, the insertion device opens a holding device of the molding board that closes the cable receptacle. The insertion device inserts the first electrical cable into the cable receptacle. After the first cable has been inserted into the cable receptacle, the holding device closes the cable receptacle again, at least partially reducing the foam material from escaping from the cable receptacle. Furthermore, this can prevent the cable from floating during foaming.

[0012] In a further embodiment, the insertion device engages in the cable receptacle, wherein the vehicle is moved along the first movement path along the cable receptacle, wherein the cable receptacle guides the insertion device and preferably the vehicle in the transverse direction.

[0013] In a further embodiment, a first vehicle position of the vehicle in a room of a building is determined by means of a position determining device, wherein the vehicle is controlled depending on the determined first vehicle position.

[0014] In a further embodiment, the vehicle is moved to a fastener storage facility, wherein the insertion device receives at least one fastener from the fastener storage facility, wherein the vehicle is moved from the fastener storage facility to the forming board, wherein the insertion device of the vehicle positions the fastener on the forming board in a predefined storage position, wherein the fastener is connected to the first electrical cable.

[0015] The system for producing the cable harness comprises a vehicle, a forming board, a cable storage and a control unit, wherein the vehicle is a non-rail-bound vehicle or an unmanned aerial vehicle, wherein the control unit is connected to the vehicle via a data connection and is designed to control the vehicle, wherein at least one first electrical cable, preferably a plurality of first electrical cables, are arranged in the cable storage, wherein the forming board has at least one cable receptacle, wherein the vehicle has at least one insertion device, wherein the system is designed to carry out the method described above.

[0016] In another embodiment, the non-rail vehicle is an autonomously driving land vehicle, an autonomously driving small vehicle, or an unmanned land vehicle. In another embodiment, the aircraft is a small aircraft, an unmanned aerial vehicle, a multicopter, or a quadcopter.

[0017] In a further embodiment, the system comprises a position-determining device, wherein the position-determining device is connected to the control unit, wherein the position-determining device is designed to determine a first vehicle position of the vehicle in the space within a building, wherein the position-determining device is designed to provide first information about the first vehicle position of the vehicle to the control unit, wherein the control unit is designed to detect the provided first information and to control the vehicle on the basis of the determined first vehicle position and the predefined first movement path.

[0018] In a further embodiment, the system comprises a further vehicle, wherein the further vehicle has a further insertion device, wherein the further vehicle is designed to be moved to the cable storage, wherein a second electrical cable is deposited in the cable storage, wherein the further vehicle is designed to pick up at least the second electrical cable from the cable storage by means of the further insertion device and to transport it from the cable storage to the forming board, wherein the position determining device is designed to determine a second vehicle position of the further vehicle in the space within the building, wherein the position determining device is designed to provide a second item of information about the second vehicle position of the further vehicle to the control unit, wherein the control unit is designedto detect the provided second information and to control the additional vehicle based on the determined second vehicle position and the predefined second movement path, wherein the control unit controls the vehicle and the additional vehicle such that the vehicle and the additional vehicle maintain a predefined minimum distance from each other. This allows the electrical cables to be laid particularly quickly.

[0019] In a further embodiment, the further insertion device is designed to insert the second electrical cable into the cable receptacle of the forming board along the second predefined movement path.

[0020] In a further embodiment, the cable receptacle is channel-shaped, in particular groove-shaped, wherein the cable receptacle has at least one side surface, wherein the side surface at least partially delimits a molding space of the cable receptacle, wherein the insertion device is designed to insert the first electrical cable into the cable receptacle, wherein the side surface extends in the longitudinal direction of the cable receptacle, wherein the insertion device is designed to engage in the cable receptacle and to bear against the side surface, wherein the bearing action guides the vehicle in a movement along the cable receptacle in the transverse direction through the insertion device.

[0021] In a further embodiment, the cable receptacle is fork-shaped, wherein the insertion device is designed to suspend the first electrical cable in the fork-shaped cable receptacle.

[0022] The invention is explained in more detail below with reference to the figures. These show: Fig. 1 is a schematic plan view of a system according to a first embodiment; Fig. 2 a section of a sectional view along a Fig. 1 shown section plane AA through a Fig. 1 shown form board of the in Fig. 1 shown system; Fig. 3 a perspective view of a Fig. 1 shown first vehicle in an exemplary embodiment; Fig. 4 a perspective sectional view of a section through a cable harness according to a first embodiment produced with the system according to the Fig. 1 to 3; Fig. 5 which in Fig. 1 shows a schematic representation of the system with a first movement path of the first vehicle; Fig. 6 a flow diagram of a process for producing the Fig. 4 with the wiring harness shown in the Fig. 1 to 3 shown system; Fig. 7 is a perspective view of a vehicle according to a second embodiment of the Fig. 1 to 3 shown system; Fig. 8 is a perspective view of a vehicle according to a third embodiment; Fig. 9 is a schematic representation of a system according to a second embodiment; and Fig. 10 is a schematic representation of a system according to a third embodiment.

[0023] The following figures refer to a coordinate system. The coordinate system is designed, for example, as a right-handed system and includes an x-axis (longitudinal direction), a y-axis (transverse direction), and a z-axis (height direction).

[0024] Fig. 1 shows a schematic plan view of a system 10 according to a first embodiment.

[0025] The system 10 is arranged in a room 15 of a building 20. The system 10 comprises a first vehicle 25, a forming board 30, a cable storage 35, a control unit 40, and a position determining device 45.

[0026] The first vehicle 25 in the embodiment is, by way of example, an aircraft, in particular a small aircraft, in particular an unmanaged aerial vehicle (UAV), in particular a multicopter, particularly advantageously, as in Fig. 1, a quadcopter. Of course, it is also conceivable that the first vehicle 25 is designed differently. For example, the first vehicle 25 can be designed as a land vehicle. For example, the first vehicle 25 can be a mobile robot, in particular an autonomously driving land vehicle, expediently an autonomously driving small vehicle, in particular an unmanned land vehicle.

[0027] The first vehicle 25 has an insertion device 50. The insertion device 50 can, for example, have a gripper arm and / or a cable reel holder. It is also conceivable for the insertion device 50 to be designed differently and to include additional or alternative components. The first vehicle 25 also has a vehicle control unit 55. The vehicle control unit 55 has a first interface 60, a first control unit 65, and a first data memory 80. A movement program, preferably a stabilization program, can be stored in the first data memory 80, for example. The movement program can, for example, be designed as a computer-implemented algorithm, in particular as control software.

[0028] The first data memory 80 is connected to the first control unit 65 via a first connection 85. The first control unit 65 is connected to the first interface 60 via a second connection 90.

[0029] The first vehicle 25 has at least one drive motor 70, preferably four drive motors 70 in the embodiment. Furthermore, the first vehicle 25 can have an energy storage device 75, preferably an electrical energy storage device 75. Additionally, the first vehicle 25 can have (mechanical / aerodynamic) control devices (not shown).

[0030] Each of the drive motors 70 is connected to the first interface 60 via a first power connection 95. Furthermore, the first interface 60 is electrically connected to the power supply 75 via a second power connection 100. The first and second power connections 95, 100 are designed to conduct electrical energy from the electrical power supply 75 to the drive motor 70. The first control unit 65 is designed to control the electrical energy transmitted to the drive motor 70 based on the movement program stored in the first data memory 80 and to control the drive motor 70 via the electrical energy provided to the drive motor 70. Each of the drive motors 70 drives a rotor 71 of the first vehicle 25.If sufficient electrical energy is supplied to the drive motors 70, the drive motors 70 generate sufficient lift via the rotors 71 so that the first vehicle 25 flies. The control of the drive motors 70 to carry out the movement in space 15 can be achieved by varying the speed of the respective drive motor 70 compared to the speed of the other drive motors 70. If, for example, the speed of all drive motors 70 is identical, the first vehicle 25 hovers in one position. If the speed of a drive motor 70 is increased, this leads to a tilting movement of the first vehicle 25, since the increased speed of the corresponding drive motor 70 increases the lift via the rotor 71 by the drive motor 70 on that particular side of the vehicle 25. Depending on the control of the drive motors 70, the first vehicle 25 can hold a position or be moved in space 15.The first vehicle 25 can perform a movement in the three spatial directions of the coordinate system sequentially or simultaneously. Furthermore, rotations around the three spatial directions are also possible by appropriately controlling the drive motors 70 by the first control unit 65. The movement / rotation of the first vehicle 25 also allows the insertion device 50 to be pivoted in space 15.

[0031] In the embodiment, the form board 30 is, for example, rectangular in shape in a plan view. The form board 30 has an upper side 105, wherein the upper side 105 extends in an xy plane and thus runs parallel, for example, to a floor 110 of the building 20.

[0032] The mold board 30 has a cable receptacle 115. The cable receptacle 115 is groove-shaped. The mold board 30 can, for example, be plate-shaped and comprise a plastic material. For example, the cable receptacle 115 can be milled into the material of the mold board 30.

[0033] The cable receptacle 115 has a first side surface 130 laterally delimiting the cable receptacle 115 and a second side surface 125. The cable receptacle 115 can be open or closed on the upper side 105 of the mold board 30. On the underside, the cable receptacle 115 is delimited by a receiving base 130. The receiving base 130 runs, for example, parallel to the upper side 105 and is offset downwards in the z-direction (in Fig. 1 on a side facing away from the viewer) to the top side 105. The side surfaces 120, 125 run parallel to each other at least in sections, so that the cable receptacle 115 has a rectangular cross-section. The cable receptacle 115 can be closed at the respective ends of the cable receptacle 115.

[0034] The cable receptacle 115 has a first receiving section 135 and at least one second receiving section 140. In the exemplary embodiment, a third receiving section 145 is provided. The receiving sections 135, 140, 145 are exemplary of a geometric configuration of the cable receptacle 115. Of course, it is also conceivable for the cable receptacle 115 to be designed differently.

[0035] In the embodiment, the first receiving portion 135 extends substantially longitudinally, while the second receiving portion 140 is connected to the first receiving portion 135 at one end and extends inclined away from the first receiving portion 135. The third receiving portion 145 may be arranged flush with the first receiving portion.

[0036] The cable storage 35 is arranged in spatial proximity, i.e., for example, at a distance of 50 cm to 10 m, from the forming board 30. In the embodiment, the cable storage 35 has at least a first storage section 155 and, for example, a second storage section 160. The number of storage sections 155, 160 is exemplary. For example, the cable storage 35 can also have a plurality of storage sections 155, 160. It is also conceivable that only a first storage section 155 is provided in the cable storage 35. The cable storage 35 can also have a collecting container 161.

[0037] A first electrical cable 165 is stored in the first storage section 155. Preferably, a plurality of first electrical cables 165 are stored in the first storage section 155. The first storage section 155 can, for example, have a first magazine of first electrical cables 165, wherein the first magazine serves to ensure that only one first electrical cable 165 can be removed from the first storage section 155 at a time. The first magazine has been pre-loaded, for example. The first electrical cable 165 can, for example, be wound up on a first drum in the first magazine. The first electrical cable 165 can also be unwound and accommodated in the first magazine in strand form.

[0038] The first electrical cable 165 is cut to a predefined length. A contact element (not shown) can be provided at least at one end of the first cable 165. Fig. 1). Of course, it is also conceivable that the ends are free of contact elements or that a contact element is attached to each end.

[0039] The contact element can be designed, for example, as a socket contact or a plug contact. The first electrical cable 165 can be designed as a single-core cable. Of course, the first electrical cable 165 can also be designed as a multi-core cable, wherein the respective cores of the first electrical cable 165 are electrically insulated from one another. The respective cores of the first cable 165 can be twisted together. The first electrical cable 165 can also be designed as a coaxial cable.

[0040] A second electrical cable 170, preferably a plurality of identically configured second electrical cables 170, is arranged in the second storage section 160. The second storage section 160 is, for example, configured as a cylindrical tube and can be configured identically to the first storage section 155. Likewise, the second storage section 160 can have a second magazine, wherein a plurality of second electrical cables 170 are stored in the second magazine, wherein the second magazine is configured such that only one second electrical cable 170 can be removed from the second magazine at a time.

[0041] The second electrical cable 170 is preferably configured differently from the first electrical cable 165. The configurations explained for the first electrical cable 165 are also possible for the second electrical cable 170. Furthermore, the only difference between the first electrical cable 165 and the second electrical cable 170 may be that the first and second electrical cables 165, 170 have a different color in their sheathing.

[0042] Furthermore, the cable storage 35 can have a sensor system to determine the loading of the magazines of the storage sections 155, 160.

[0043] Furthermore, the system 10 can include a fastener storage 36. The fastener storage 36 is arranged at a distance from, but in proximity to, the forming board 30 and the cable storage 35. At least one fastener 39, preferably a plurality of fasteners 39, is stored in the fastener storage 36, for example, in a third magazine, wherein the third magazine is configured to provide only a single fastener 39 at a time.

[0044] The control unit 40 has a second interface 175, a second data memory 180, and a second control unit 185. The second data memory 180 is connected to the second control unit 185 via a third connection 190. The second interface 175 is connected to the second control unit 185 via a fourth connection 195.

[0045] At least a first movement path 200 is stored in the second data storage 180. Additionally, a second control program can be stored in the second data storage 180. The second control program can be designed as a computer-implemented algorithm. Additionally, a collision avoidance algorithm can be stored in the second data storage 180. The collision avoidance algorithm can be integrated into the second control program or be called by the second control program.

[0046] The position determination device 45 is connected to the second interface 175 of the control device 40 by means of a fifth connection 205.

[0047] The position-determining device 45 can have one or more cameras 210. The camera 210 detects at least one permissible movement area 215 in the space 15, which the first vehicle 25 may not leave under any circumstances. The position-determining device 45 further has an image processing unit 220. The image processing unit 220 is connected to the second interface 175 of the control unit 40 via the fifth connection 205 and to the camera 210 via a sixth connection 225. If multiple cameras 210 are provided, multiple sixth connections 225 are provided to connect the cameras 210 to the image processing unit 220.

[0048] The camera 210 captures the movement space 215 and provides at least one image of the movement space 215, preferably images captured in quick succession, preferably as a video, to the image processing unit 220 via the sixth connection 225. If multiple cameras 210 are present, the cameras 210 are arranged at a distance from one another and capture the movement space 215 of the system 10 from their respective viewing angles, each providing images to the image processing unit 220.

[0049] The image processing unit 220 is designed to calculate a first vehicle position of the first vehicle 25 in the movement space 215 based on the provided images.

[0050] The position-determining device 45 can also be configured differently. For example, the position-determining device 45 can comprise, in addition to or as an alternative to the camera 210, a laser scanner or a laser scanner arrangement, a lidar, and / or a radar. The position-determining device 45 can also be attached to the vehicle 25 and determine the first vehicle position from the first vehicle 25.

[0051] The second interface 175 is connected to the first interface 60 of the vehicle control unit 55 of the first vehicle 25 by means of a seventh connection 250. The first to seventh connections 85, 90, 190, 195, 205, 225, 250 can be configured as wired or wireless data connections. Data transmission via the first to seventh connections 85, 90, 190, 195, 205, 225, 250 can be analog and / or digital. A transmission of electrical energy for driving, for example, the drive motor 70 or for operating the vehicle control unit 55 or the control unit 40 takes place separately and not via the first to seventh connections 85, 90, 190, 195, 205, 225, 250, but via the power connection 95, 100.

[0052] Fig. 2 shows a section of a sectional view along a Fig. 1 shown section plane AA through the Fig. 1 shown form board 30.

[0053] The mold board 30 can additionally have a holding device 230 arranged on the upper side 105, wherein the holding device 230 has, for example, a first holding element 235 and a second holding element 240, wherein the holding elements 235, 240 are fastened to the upper side 105 of the mold board 30. The first side surface 120, together with the second side surface 125 and the receiving base 130, delimits a molding space 134. The molding space 134 is at least partially closed on the upper side at the opening 245 by the holding device 230.

[0054] The holding elements 235, 240 extend over an opening 245 of the molding space 134 of the cable receptacle 115 on the upper side 105 and close the opening 245. The first holding element 235 is arranged on the upper side adjacent to the first side surface 120, and the second holding element 240 is arranged on the upper side adjacent to the second side surface 125. Only one of the two holding elements 235, 240 can be provided, or the holding device 230 can be omitted. Other configurations of the holding device 230 are also conceivable. The holding elements 235, 240 can be brush-like or rib-like.

[0055] The holding device 230 preferably closes the cable receptacle 115 over the entire receptacle sections 135, 140, 145.

[0056] Fig. 3 shows a perspective view of the Fig. 1 shown first vehicle 25 in an exemplary embodiment.

[0057] The first vehicle 25 is in the embodiment as already shown in Fig. 1, is designed as a quadcopter. Of course, another design of the first vehicle 25 is also conceivable.

[0058] In addition to the drive motor 70 and the vehicle control unit 55, the first vehicle 25 has a vehicle structure 255. The vehicle structure 255 can be designed as a vehicle frame. The vehicle structure 255 can also be designed, for example, as a self-supporting body of the first vehicle 25. In the embodiment, the vehicle structure 255 has a frame 260, with a drive motor 70 arranged on the upper side of the frame 260 on each outrigger 265 of the frame 260.

[0059] The vehicle control unit 55 and the electrical power supply 75 can be arranged in the first vehicle 25 near the center of gravity of the first vehicle 25. Furthermore, the insertion device 50 has a fastening pin 270 on the underside of the frame 260. The fastening pin 270 has an actuator 275 and a holding means 280 connected to the actuator 275, for example a holding lug 280, which is connected to the actuator 275. The actuator 275 can be connected to the electrical power supply 75 by means of a third power connection (in Fig. 3) may be electrically connected to the first interface 60. The actuator 275 is mechanically connected to the holding means 280. The actuator 275 is movable between a first actuator position and a second actuator position, wherein in the first position the holding means 280 assumes a first holding position and in the second actuator position of the actuator 275 the holding means 280 assumes a second holding position.

[0060] The holding means 280 is arranged on the underside of the fastening mandrel 270. On the upper side, Fig. 3 the fastening mandrel 270 is mechanically connected to the frame 260.

[0061] In the embodiment, the first electrical cable 165 is wound on a first cable drum 285. The first cable drum 285 has a mandrel receptacle 290 (in Fig. 3 (indicated by dashed lines running centrally along the first cable drum 285), through which the fastening mandrel 270 extends. On the underside, the first cable drum 285 is fastened to the fastening mandrel 270 in the first holding position of the holding means 280. On the upper side, the first cable drum 285 can rest on the end face of the actuator 275, so that an axial position relative to the fastening mandrel 270 of the first cable drum 285 is fixed. The first cable drum 285 is rotatably mounted on the fastening mandrel 270, so that the first electrical cable 165 can be unwound from the first cable drum 285.

[0062] In addition, the insertion device 50 can also have a guide element 295, wherein the guide element 295 is arranged at a distance from the first cable drum 285 and is connected to the frame 260. The guide element 295 can, for example, be designed as a sleeve or a groove, with the first electrical cable 165 being guided in the guide element 295 in the exemplary embodiment. The guide element 295 can, of course, also be omitted.

[0063] Of course, it is also conceivable that the insertion device 50 is designed differently. For example, it is conceivable that the insertion device 50 has a gripping arm that is connected to the frame 260 at one end. On the other side, the gripping arm can have a gripper that, in a first holding position, encompasses the first electrical cable 165 around its circumference and thereby secures it.

[0064] In a second holding position of the holding means 280, the actuator 275 is in the second actuator position. In the second holding position, for example, the holding means 280 is moved inward, so that the first cable drum 285 can be pulled downward from the fastening mandrel 270. In the second holding position, the first cable drum 285 and the first electrical cable 165 are thus detached from the first vehicle 25.

[0065] If the gripper is provided in the alternative embodiment of the insertion device 50, the gripper is opened in the second holding position so that the first electrical cable 165 is released from the gripper.

[0066] Fig. 4 shows a perspective cross-section of a section of a cable harness 300 according to a first embodiment.

[0067] The cable harness 300 includes at least the first electrical cable 165 and the second electrical cable 170. The first electrical cable 165 and the second electrical cable 170 extend parallel to one another in sections. In the embodiment, the first electrical cable 165 and the second electrical cable 170 are embedded in a first sheath 305. The first sheath 305 can, for example, comprise a foam material, in particular a closed-cell foam, in particular a polyurethane foam.

[0068] The first electrical cable 165 further comprises a first electrical conductor 310 and a second sheath 315. The first electrical conductor 310 is circumferentially sheathed by the second sheath 315. The second sheath 315 is already applied to the first electrical conductor 310 when the first electrical cable 165 is located in the cable storage 35.

[0069] The second electrical cable 170 has a second electrical conductor 320 and a third sheath 325, wherein the second and third sheaths 315, 325 have a dielectric as their material. The second electrical conductor 320 is also already sheathed by the third sheath 325 when the second electrical cable 170 is stored in the cable storage 35.

[0070] In the embodiment, the first electrical cable 165 and the second electrical cable 170 are completely embedded in the first sheath 305. The first sheath 305 has a substantially rectangular configuration corresponding to the configuration of the molding cavity 134. The first sheath 305 mechanically connects the first electrical cable 165 to the second electrical cable 170. Furthermore, the first sheath 305 protects the first and / or second electrical cables 165, 170 from mechanical damage and / or from thermal and chemical influences. This ensures reliable electrical transmission via the first electrical conductor 310 and the second electrical conductor 320, respectively.

[0071] Fig. 5 shows the Fig. 1 shows a schematic representation of the system 10 with a first movement path 200 of the first vehicle 25.

[0072] In Fig. 5, the first movement path 200 is shown by a dashed line. The movement path 200 is divided into individual first to sixth sections 330, 335, 340, 345, 350, 355, which are interconnected. Beginning with a starting position 430, the movement path runs along a first to sixth path position 400, 410, 415, 420, 425, 435.

[0073] Fig. 6 shows a flow diagram of a method for producing the Fig. 4 shown wiring harness 300 with the one shown in the Fig. System 10 shown in Figures 1 to 3 and 5.

[0074] In a first method step 500, the first electrical cable 165 is cut to length, and if necessary, the contact element is attached, for example, crimped, to the respective ends of the first cable 165. Furthermore, each of the first electrical cables 165 can be wound onto a first cable drum 285. The first electrical cable 165 is stored in the first magazine or in the first storage section 155. Alternatively, the first electrical cable 165 can be stretched in the longitudinal direction, i.e., unwound, and stored in the first storage section 155.

[0075] Furthermore, in the first method step 500, the second electrical cable 170 is also cut to length and preferably a contact element is attached, preferably crimped, to the respective ends of the second cable 170. A second electrical cable 170 can also be wound on a second cable drum 326 (in Fig. 1 and Fig. 5) and stored in the second storage section 160. The second electrical cable 170 can also be laid down and stored in the second storage section 160 in a longitudinally stretched manner, i.e., not wound up.

[0076] In a second method step 505 following the first method step 500, the control unit 40 starts the first vehicle 25 from the starting position 430 using its start signal. The starting position is located within the movement space 215. To start the vehicle 25, the drive motors 70 are supplied with energy from the energy supply 75 via the power connection 95, 100. The first control unit 65 controls the drive motors 70 based on the control program stored in the first data memory 80 such that the first vehicle 25 moves, preferably flies in this embodiment, from the starting position 430 to the first storage section 155 along a first section 330 of the first movement path 200. During all method steps 500-555, the first vehicle position of the first vehicle 25 is continuously determined by the position-determining device 45, and the determined first vehicle position is provided to the control unit 40.The control unit 40 and / or the vehicle control unit 55 takes the determined current vehicle position into account when controlling the first vehicle 25. The first section 330 can be a straight-line connection between the starting position 430 and a first path position 400 on the first bearing section 155. To avoid collisions, the first section 330 can also be delimited, as symbolically shown in FIG. Fig. 5, be curved, wherein in the embodiment example the flight is carried out laterally around the forming board 30.

[0077] Furthermore, the current position can be taken into account within the framework of the collision avoidance algorithm in order to avoid a collision of the first vehicle 25 with another component of the system 10, for example with the mounting bearing 36.

[0078] In a third method step 510 following the second method step 505, the second control unit 185 controls the first control unit 65 by means of a first control signal to receive the first cable drum 285 from the first storage section 155 with the first electrical cable 165.

[0079] To this end, the vehicle control unit 55 controls the drive motors 71 such that, in order to pick up the first cable drum 285 from the first storage section 155, the first vehicle 25 hovers above the cable storage 35 and is lowered slightly. As the first vehicle 25 descends, it guides the fastening mandrel 270 through the mandrel receptacle 290. The actuator 275 is controlled by the vehicle control unit 55 such that it moves into the second actuator position and, with it, the holding means 280 is also moved into the second holding position. As a result, as the first vehicle 25 descends, the fastening mandrel 270 can be guided through the mandrel receptacle 290 of the first cable drum 285.

[0080] If the fastening mandrel 270 is fully inserted into the mandrel receptacle 290, the vehicle control unit 55 controls the actuator 275 such that the actuator 275 moves from the second actuator position to the first actuator position and, in the process, moves the holding means 280 from the second holding position to the first holding position, so that the first cable drum 285 is fastened to the fastening mandrel 270.

[0081] In a fourth method step 515, the first control unit 65 confirms the pickup of the first cable drum 285 via the second control unit 185 by means of a pickup signal.

[0082] The control unit 40 then controls the vehicle control unit 55 using a second control signal and based on the first movement path 200 stored in the second data memory 180 such that the vehicle control unit 55 moves the first vehicle 25 from the first path position 400 along a second section 335 of the movement path 200 toward the mold board 30 into a second path position 410. The second path position 410 can be arranged at a longitudinal end of the first receiving section 135. In this case, the first vehicle 25 can be arranged in the second path position 410 with the guide element 295 above the first receiving section 135.

[0083] In a fifth method step 520, the insertion device 50 is activated by the control unit 40 via the vehicle control unit 55, so that the insertion device 50 inserts the first electrical cable 165 into the cable receptacle 115.

[0084] The insertion device 50 can open the holding device 230 and thread the first electrical cable 165 past the holding elements 235, 240 into the molding chamber 134, as well as insert the first electrical cable 165 into the molding chamber 134. This can be achieved, for example, by the guide element 295 pressing downward against the holding device 230, so that the holding elements 235, 240 pivot reversibly downward into the cable receptacle 115 and expose the opening 245. Due to the elastic design of the holding elements 235, 240, the holding elements 235, 230 pivot back to their original position after passing the guide element 295 and close the molding chamber 134 at the top at the opening 245.

[0085] When inserting the first electrical cable 165 into the forming space 134, the first vehicle 25 moves over the forming board 30 along the third section 340 of the first movement path 200. The third section 340 of the first movement path 200 runs, for example, parallel to the first receiving section 135. At the end of the first receiving section 135, the first vehicle 25 reaches a third path position 415.

[0086] At the third path position, the control unit 40 controls the vehicle control unit 55 using a third control signal to change a direction of movement of the first vehicle 25. Subsequently, the first vehicle 25 moves along a fourth section 345 of the first movement path 200 toward a fourth path position 420. Here, too, the insertion device 50 inserts the first electrical cable 165 into the cable receptacle 115. At the end of the second receptacle section 140, the first vehicle 25 reaches the fourth path position 420, which completes the insertion process of the first cable 165 into the forming space 134 of the forming board 30.

[0087] In a sixth method step 525, the control unit 40 controls the vehicle control unit 55 by means of a fourth control signal such that the first vehicle 25 flies from the fourth path position 420 at the end of the second receiving section 140 along a fifth section 350 to a fifth path position 425 at the cable storage 35. The collection container 161 is located at the fifth path position 425. The fifth section 350 runs parallel to the third receiving section 145.

[0088] In a seventh method step 530, in the fifth path position 425, the holding element 235 is moved from the first holding position to the second holding position, thereby releasing the empty first cable drum 285. The first cable drum 285 falls, for example, into the collection container of the cable storage 35. In the fifth path position 425, the first vehicle 25 can hover above the cable storage 35.

[0089] In order to lay a plurality of first electrical cables 165, the second to seventh method steps 505 - 530 are repeated, wherein the first section 330 of the first movement path 200 is adapted such that the sixth path position 435 is used as the starting position 430.

[0090] Once all first electrical cables 165 have been laid, in a final step 560, after the first cable drum 285 has been released, the first vehicle 25 can be moved to a sixth path position 435 along a sixth section 355 of the first movement path 200. The sixth path position 435 can correspond to the starting position 430. At the sixth path position, the first vehicle 25 can be deactivated and parked.

[0091] Fig. 7 shows the Fig. 1 shows a schematic representation of the system 10 with a second movement path 201 of the first vehicle 25.

[0092] To lay the second cable 170, the second to seventh method steps 505-530 are repeated essentially identically. In contrast to the method steps 505-530 explained above, the control unit 40 controls the vehicle control unit 55 such that the first vehicle 25 is moved along the second movement path 201.

[0093] The second movement path 201 is partially identical to the first movement path 200. In contrast, the fifth path position 425 serves as the starting position 430. Furthermore, the first path position 400 is arranged on the second bearing section 160.

[0094] In the second method step 505, the first vehicle 25 is moved to the second storage section 160, wherein in the third method step 510, a second cable drum 286 with the second electrical cable 170 is picked up.

[0095] In the fourth method step 515, the vehicle is further moved along the second movement path 201 and the second electrical cable 170 is inserted into the first receiving section 135.

[0096] When the fourth path position 420 is reached, the control device 40 controls the first vehicle 25 such that the vehicle 25, with the insertion device 50, inserts the second electrical cable 170 into the third receiving section 145. Here, the first vehicle 25 follows a fifth section 350 of the second movement path 201 instead of the fourth section 345.

[0097] In a fourth method step 515, when the fifth position 420 at the end of the third receiving section 145 is reached, the insertion device 50 ends the insertion of the second cable 170 into the cable receptacle 115.

[0098] In the sixth method step 525, the first vehicle is moved back along the fifth section 350 to the cable storage 35.

[0099] The second to seventh method steps 505 - 530 are repeated for the second electrical cable 170 until all first and second electrical cables 165, 170 are inserted into the cable receptacle 115.

[0100] In an eighth method step 535 following the seventh method step 530, the first vehicle 25 is moved from the fifth position 425 along a sixth section 355 of the third movement path 202 (dash-dotted in Fig. 7) to a sixth path position 435 on the fastener bearing 36

[0101] In a ninth method step 540 following the eighth method step 535, the insertion device 50 receives a fastening means 39 from the fastening bearing 36.

[0102] In a tenth method step 545, the first vehicle 25 is moved between the sixth path position 435 and a storage position 440 along a seventh section 360 of the third movement path 202 and an eighth section 365, wherein in the storage position 440, the fastening means 39 is introduced into the mold space 134. The tenth method step 545 is repeated for all necessary fastening means 39, with the respective storage position 440 being varied. The final step 560 can then be performed, and the first vehicle 25 can be parked.

[0103] In an eleventh method step 550, a foam material is introduced into the mold cavity 134. The foam material flows around the electrical cables 165, 170 and the fastening means 39, expands, and preferably completely fills the mold cavity 134. The holding device 230 prevents the electrical cables 165, 170 from floating on the foam material and from being embedded in the foam material. The foam material is further cured and connects the electrical cables 165, 170 to each other and to the fastening means 39.

[0104] In a twelfth method step 555, the cable harness 300 is removed from the mold cavity 134. Furthermore, in the twelfth method step 555, a contact housing can be attached to each of the contact elements of the electrical cables 165, 170 after curing.

[0105] Fig. 8 shows a perspective view of a first vehicle 25 according to a second embodiment.

[0106] In the embodiment, the first vehicle 25 is designed as a land vehicle. When carrying out the Fig. In the method shown in Figure 6, the vehicle 25 drives rather than flies along the surface 105 of the mold board 30. Furthermore, the cable storage 35 and / or the fastener storage 36 are arranged directly adjacent to the mold board 30 and are configured such that the cable storage 35 and / or the fastener storage 36 can be approached without barriers for the vehicle 25.

[0107] In this embodiment, the first vehicle 25 has two laterally arranged wheels 600. Each of the wheels 600 is connected to and driven by a drive motor 70. In addition, the insertion device 50 is arranged at the rear of the vehicle 25. When carrying out the method described above, the insertion device 50 engages in the forming space 134 as it travels along the upper side 105 of the forming board 30. By engaging in the forming space 134, a rear of the vehicle 25 is guided in the transverse direction as it travels along the cable receptacle 115 in the transverse direction by contact of the insertion device 50 with at least one of the two side surfaces 120, 125. This ensures secure insertion of the cable 165, 170 into the cable receptacle 115.

[0108] Fig. 9 shows a perspective view of a vehicle 25 according to a third embodiment.

[0109] Vehicle 25 is essentially identical to the one in Fig. 7 shown (land) vehicle 25. In contrast, the Fig. 9, the first vehicle 25 lacks the wheels 600, and the wheels are replaced by at least four, preferably at least six, legs 605. The legs 605 give the first vehicle 25 an insect-like configuration. The legs 605 can be driven separately from one another. This allows the vehicle 25 to also overcome steps on the upper side 105 of the molded board 30.

[0110] Fig. 10 shows a schematic representation of a system 10 according to a second embodiment.

[0111] System 10 is essentially identical to that used in the Fig. 1 to 3 and 5. In the following, only the deviations of the system 10 shown in Fig. 10 compared to the system shown in the Fig. 1 to 5 shown system 10.

[0112] The upper side 105 of the molding board 30 is essentially flat, as an example. The molding board 30 has a plurality of spaced-apart forks 610. Each of the forks 610 is Y-shaped and has a fork base 615, which is connected to the upper side 105. Each fork 610 defines the cable receptacle 115 on its upper side with two fork arms.

[0113] Will the above in Fig. 6 described procedure with the in Fig. 10, the first vehicle 25 flies along the first and second movement paths 200, 201 and hooks the electrical cable 165, 170 into the forks 610. Due to the Y-shaped configuration, the insertion device 50 can particularly easily hook the electrical cable 165, 170 into the cable receptacle 115 of the forks 610.

[0114] When carrying out the Fig. In the method described in Figure 6, instead of introducing the foam material to form the first sheath 305, the first sheath 305 is provided in a strip-like manner, and the electrical cables 165, 170 are wound with the strip-like first sheath 305 to form the cable harness 300. This can be done, for example, using an automatic winding machine.

[0115] The above-described embodiments of the system 10 and the method have the advantage that the wire harness 300 can be manufactured fully automatically. This allows for a higher cycle rate for manufacturing the wire harness 10 compared to manual manufacturing. Furthermore, greater process reliability is achieved.

[0116] Fig. 11 shows a schematic representation of a system 10 according to a third embodiment.

[0117] The Fig. The system 10 shown in Figure 11 is essentially identical to that shown in Fig. 1 to 3, 5 and 6. In the following, only the differences of the system 10 shown in Fig. 10 compared to the system shown in the Fig. 1 to 3, 5 and 6 shown system 10.

[0118] In addition to the first vehicle 25, the system 10 has at least one second vehicle 700. The second vehicle 700 is, for example, identical to the first vehicle 25 and is connected to the second interface 175 via an eighth connection 705, which is configured as a data connection. Furthermore, the second vehicle 700 has a second insertion device 710.

[0119] The first vehicle 25 and the second vehicle 700 together carry out the Fig. 6. For example, the first vehicle 25 can lay the first electrical cable 165, and the second vehicle 700 can lay the second electrical cable 170 using a second insertion device 710, wherein, for example, the second vehicle 700 is moved only along the second movement path 201 and the first vehicle 25 is moved only along the first movement path 200. The first movement path 200 and the second movement path 201 are identical in sections.

[0120] By moving the second vehicle 700 along the second movement path 201, the second vehicle 700 can pick up at least the second electrical cable 170 from the cable storage 35 by means of the second insertion device 710 and transport it from the cable storage 35 to the forming board 30. The position-determining device 45 continuously determines a second vehicle position of the second vehicle in the room 15 within the building 20 for controlling the second vehicle 700. The position-determining device 45 provides second information about the second vehicle position of the second vehicle 700 to the control unit 40.

[0121] The control unit 40 detects the second vehicle position in order to control the second vehicle 700 along the second movement path 201 based on the determined second vehicle position of the second vehicle 700 and the predefined second movement path 201. The collision avoidance algorithm of the control unit 40 ensures that the first vehicle 25 and the second vehicle 700 maintain a minimum distance from each other to avoid a collision.

[0122] Instead of the Fig. 11, additional vehicles can also be provided. The vehicles 25, 700 can also be designed differently from one another. For example, one of the vehicles 25, 700 can be designed as shown in Fig. 1 and another of the vehicles 25, 700 as in the Fig. 8 or Fig. 9 be trained. List of reference symbols 10 systems 15 rooms 20 buildings 25 first vehicle 30 molding board 35 cable storage 36 fastener bearings 39 fasteners 40 Control unit 45 Positioning device 50 Insertion device 55 Vehicle control unit 60 first interface 65 first control unit 70 drive motor 71 Rotor 75 Energy supply 80 first data storage 85 first connection 90 second connection 95 first power connection 100 second power connection 105 Top 110 Floor 115 cable holder 120 first side surface 125 second side surface 130 Reason for admission 134 Forming room 135 first recording section 140 second recording section 145 third recording section 155 first camp section 160 second camp section 165 first cable 170 second cable 175 second interface 180 second data storage 185 second control unit 190 third connection 195 fourth connection 200 first movement path 201 second movement path 205 fifth connection 210 Camera 215 exercise space 220 image processing unit 225 sixth connection 230 Holding device 235 first holding element 240 second holding element 245 Opening 250 seventh connection 255 Vehicle structure 260 frames 265 booms 270 fixing mandrel 275 Actuator 280 holding devices 285 first cable drum 286 second cable drum 290 mandrel holder 295 guide element 300 wiring harness 305 first sheath 310 first electrical conductor 315 second sheath 320 second electrical conductor 325 third sheath 326 second cable drum 330 first section 335 second section 340 third section 345 fourth section 350 fifth section 355 sixth section 400 first position 405 second position 410 third position 415 fourth position 420 fifth position 425 sixth position 430 starting position 500 first process step 505 second procedural step 510 third procedural step 515 fourth procedural step 520 fifth procedural step 525 sixth procedural step 530 seventh procedural step 535 eighth procedural step 540 ninth procedural step 600 wheels 605 Leg 700 second vehicle 705 eighth connection 710 second facility

Claims

[1] Method for the automated production of a cable harness (300), - wherein a vehicle (25), a mold board (30) and a cable storage (35) are provided, - wherein the vehicle (25) is a non-rail land vehicle or an unmanned aerial vehicle, - wherein a first electrical cable (165) is stored in the cable storage (30), - wherein the vehicle (25) is moved to the cable storage (35), - wherein the vehicle (25) receives at least the first electrical cable (165) by means of an insertion device (50), - wherein the vehicle (25) is moved from the cable storage (35) to the forming board (30) and transports the received first electrical cable (165) from the cable storage (35) to the forming board (30), - wherein the vehicle (25) is moved on the forming board (30) along a predefined first movement path (200) and the insertion device (50) inserts the first electrical cable (165) into a cable receptacle (115) of the forming board (30). [2] Method according to claim 1, - wherein, after the first cable (165) has been inserted into the cable receptacle (115), the insertion device (50) is released from the first electrical cable (165) and, after the release, the vehicle (25) is moved back to the cable storage (35), - wherein at the cable storage (35) the insertion device (50) receives a second electrical cable (170) from the cable storage (35), - wherein the vehicle (25) is moved to the mold board (30) with the second electric cable (170), - wherein the vehicle (25) is moved on the forming board (30) along a predefined second movement path (201) and along the second predefined movement path the insertion device (50) inserts the second electrical cable (170) into the cable receptacle (115) of the forming board (30). [3] Method according to claim 1 or 2, - wherein the insertion device (50) inserts the first electrical cable (165) into the cable receptacle (115) substantially completely, - wherein a foam material is introduced into the cable receptacle (115), - wherein the foam material flows around the first electrical cable (165) and encloses it at least in sections, - whereby the foam material swells and hardens. [4] Method according to claim 3, - wherein the insertion device (50) opens a holding device (230) of the mold board (30) closing the cable receptacle (115), - wherein the insertion device (50) inserts the first electrical cable (165) into the cable receptacle (115), - wherein the holding device (230) closes the cable receptacle (115) again after the first cable (165) has been inserted into the cable receptacle (115) and reduces the escape of the foam material from the cable receptacle (115) at least in sections. [5] Method according to one of the preceding claims, - wherein at least the insertion device (50) engages in the cable receptacle (115) along the first movement path (200), - wherein the vehicle (25) is moved along the first movement path (200) along the cable receptacle (115), - wherein the cable holder (115) guides the insertion device (50) in the transverse direction. [6] Method according to one of the preceding claims, - wherein a first vehicle position of the vehicle (25) in a room (15) of a building (20) is determined by means of a position determining device (45), - wherein the vehicle (25) is controlled depending on the determined first vehicle position. [7] Method according to one of the preceding claims, - wherein the vehicle (25) is moved to a fastener storage facility (36), - wherein the insertion device (50) receives a fastening means (39) from the fastening means bearing (36), - wherein the vehicle (25) is moved from the fastener storage (36) to the mold board (30), - wherein the insertion device (50) of the vehicle (25) positions the fastening means (39) on the mold board (30) in a predefined storage position (440), - wherein the fastening means (39) is connected to the first electrical cable (165). [8] System (10) for producing a wiring harness (300), - comprising a vehicle (25), a mold board (30), a cable storage (35) and a control device (40), - wherein the vehicle (25) is a non-rail land vehicle or an unmanned aerial vehicle, - wherein the control unit (40) is connected to the vehicle (25) via a data connection (250) and is designed to control the vehicle (25), - wherein a first electrical cable (165) is arranged in the cable bearing (35), - wherein the molding board (30) has a cable receptacle (115), - wherein the vehicle (25) has an insertion device (50), - wherein the system (10) is designed to carry out the method according to one of the preceding claims. [9] System (10) according to claim 8, - wherein the non-rail-bound land vehicle (25) is an autonomously driving land vehicle or an autonomously driving small vehicle or an unmanned land vehicle, - or - where the aircraft is a small aircraft or an unmanned aerial vehicle (UAV) or a multicopter or a quadcopter. [10] System (10) according to claim 8 or 9, - comprising a position determining device (45), - wherein the position determining device (45) is connected to the control unit (40), - wherein the position determining device (45) is designed to determine a first vehicle position of the vehicle (25) in the space (15) within a building (20), - wherein the position determining device (45) is designed to provide first information about the first vehicle position of the vehicle (25) to the control unit (40), - wherein the control unit (40) is designed to detect the provided first information and to control the vehicle (25) on the basis of the determined first vehicle position and the predefined first movement path (200). [11] System (10) according to claim 10, - comprising another vehicle (700), - wherein the further vehicle (700) has a further insertion device (710), - wherein the further vehicle (700) is designed to be moved to the cable storage (35), - wherein a second electrical cable (170) is stored in the cable storage (35), - wherein the further vehicle (700) is designed to pick up at least the second electrical cable (170) from the cable storage (35) by means of the further insertion device (710) and to transport it from the cable storage (35) to the forming board (30), - wherein the position determining device (45) is designed to determine a second vehicle position of the further vehicle (700) in the space (15) within the building (20), - wherein the position determining device (45) is designed to provide second information about the second vehicle position of the further vehicle to the control unit (40), - wherein the control unit (40) is designed to detect the provided second information and to control the further vehicle (700) on the basis of the determined second vehicle position and the predefined second movement path (201), - wherein the control unit (40) controls the vehicle (25) and the further vehicle (700) in such a way that the vehicle (25) and the further vehicle (700) maintain a predefined minimum distance from one another. [12] System (10) according to claim 11, - wherein along the second predefined movement path (201) the further insertion device (710) is designed to insert the second electrical cable (170) into the cable receptacle (115) of the forming board (30). [13] System (10) according to one of claims 8 to 12, - wherein the cable receptacle (115) is channel-shaped or groove-shaped, - wherein the cable receptacle (115) has a side surface (120, 125), - wherein the side surface (120, 125) at least partially delimits a molding space (134) of the cable receptacle (115), - wherein the insertion device (50) is designed to insert the first electrical cable (165) into the cable receptacle (115), - wherein the side surface (120, 125) extends in the longitudinal direction of the cable receptacle (115), - wherein the insertion device (50) is designed to engage in the cable receptacle (115) and to bear against the side surface (120, 125), - wherein the vehicle (25) is guided by the insertion device (50) in a movement along the cable holder (115) in the transverse direction. [14] System (10) according to one of claims 9 to 13, - wherein the cable receptacle (115) is fork-shaped, - wherein the insertion device (50) is designed to suspend the first electrical cable (165) into the fork-like cable receptacle (115).

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