Method for determining the assembly sequence of contact carriers with individual electrical conductors

Abstract

The invention relates to a method for determining the assembly sequence of contact carriers (2 to 14) with individual electrical conductors (L1 to Ln). According to the invention, assembly parameters are determined and / or specified in a simulation of the assembly of contact carriers (2 to 14) with individual electrical conductors (L1 to Ln). Furthermore, a coordinate system is generated in the simulation whose axes (x, y, z) extend along a longitudinal direction, a transverse direction, and a vertical direction of a virtual image of a carrier plate (1).In the coordinate system, an arrangement of the contact carriers (2 to 14) on the image of the carrier plate (1) and the assembly of the contact carriers (2 to 14) with the individual wires (L1 to Ln) are simulated, and the positions and / or orientations of the contact carriers (2 to 14) on the image of the carrier plate (1) and the assembly sequence of these with the individual wires (L1 to Ln) are optimized in the simulation as a function of the assembly parameters such that the obscuring of unpopulated contacts (K1 to K4) caused by individual wires (L1 to Ln) is minimized. The invention further relates to a method for equipping contact carriers (2 to 14) with individual electrical conductors (L1 to Ln).

Description

[0001] The invention relates to a method for determining an assembly sequence of contact carriers with individual electrical lines.

[0002] The invention further relates to a method for equipping contact carriers with individual electrical lines.

[0003] It is generally known that when manufacturing cable sets or cable bundles, for example for use as wiring harnesses in vehicles, it is necessary to equip individual electrical cables with contact carriers of plugs or sockets, i.e. to make electrical contact. To equip contact carriers with cables, the contact carriers are usually provided on a carrier plate of a device, for example a system or a robot. The basic positioning of the plugs or sockets with their contact carriers, or just the contact carriers, can be freely selected within a certain range. For this assembly, the carrier plates are usually positioned vertically or at a different angle.

[0004] DE 10 2004 055 898 A1 discloses a calculation method for packing a plurality of cables forming a cable harness. In the calculation method, the sectional shapes of the cables are considered as a plurality of circles with diameters corresponding to the respective outer shapes of the cables. The calculation method comprises the following steps: - removing a first circle smaller than a predetermined value from the plurality of circles according to a predetermined reference value; - forming a primary enclosing circle as small as possible in which a plurality of second circles, which are residual circles in which the first circle is removed from the plurality of circles, are enclosed in the primary enclosing circle so that they do not overlap one another; - calculating first position information taking into account a position of the primary inclusion circle and the second circles enclosed in the primary inclusion circle; - forming a final inclusion circle as small as possible, in which the first circle is arranged in the primary inclusion circle, while the second circles are fixed in the primary inclusion circle according to the first position information, so that the first circle and the second circles do not overlap each other; - calculating a second position information taking into account a position of the final inclusion circle; and - Output the second position information.

[0005] The step of forming the primary inclusion circle and the step of forming the final inclusion circle each include the following steps: - Assuming an enclosing circle that encloses the plurality of circles arranged in such a way that the many circles in a plane do not overlap each other; - defining a target circle having the same center as the enclosing circle, the target circle being smaller than the enclosing circle, and at least one of the circles being offset from the target circle; - finding a position where the plurality of circles other than the insertion test circle are arranged as far as possible from the insertion test circle within the target circle without overlapping each other, while the circle shifted from the target circle is defined as the insertion test circle; - inserting the insertion test circle into a space within the target circle, the space being created by changing the arrangement of the multiple circles based on the search result of the search step; - defining a new target circle slightly smaller than the target circle and containing the insertion test circle when the entire part of the insertion test circle is inserted into the target circle, and returning to the search step; and - Repeat the step of defining the target circle, the search step, the insertion step and the step of defining the new target circle to gradually reduce the inclusion circle.

[0006] The invention is based on the object of providing a novel method for determining an assembly sequence of contact carriers with individual electrical lines and a novel method for equipping contact carriers with individual electrical lines.

[0007] The object is achieved according to the invention by a method for determining an assembly sequence, which has the features specified in claim 1, and by a method for assembly, which has the features specified in claim 9.

[0008] Advantageous embodiments of the invention are the subject of the subclaims.

[0009] The method for determining an assembly sequence of contact carriers with individual electrical lines is characterized according to the invention in that in a simulation of an assembly of contact carriers with individual electrical lines as assembly parameters - dimensions of a carrier plate intended for fastening several contact carriers are determined and / or specified, - a number of contact carriers to be electrically connected to the individual lines as well as their respective dimensions and arrangements of electrical contacts formed in or on the contact carriers and intended for electrical contact with the individual lines are determined and / or specified, and - a number of individual cables to be electrically connected to the contact carriers and their respective lengths are determined and / or specified.

[0010] Furthermore, the simulation is characterized by the fact that - a coordinate system is generated whose axes extend along a longitudinal direction, a transverse direction and a vertical direction of a virtual image of the carrier plate, - in the coordinate system, an arrangement of the contact carriers on the image of the carrier plate and an assembly of the contact carriers with the individual lines are simulated and - Positions and / or alignments of the contact carriers on the image of the carrier plate and the assembly sequence of these with the individual lines are optimized depending on the assembly parameters in the simulation in such a way that concealment of unpopulated contacts caused by individual lines is minimized.

[0011] The invention enables the determination of an optimized combination of the positioning and alignment of the contact carriers on a carrier plate and the assembly sequence of individual leads in these contact carriers in a simulation. The results of the simulation can then be used in a real assembly of contact carriers with individual leads to realize an optimized assembly process. By avoiding the obstruction of the contacts of the contact carriers by individual leads, the real assembly can then be carried out automatically in a simple and reliable manner.

[0012] Based on knowledge of the dimensions, including geometric data of the contact carriers, these can be clearly located in the coordinate system on the image of the carrier plate, for example, using an automated algorithm. This also makes it possible to clearly and relatively identify all contacts of the contact carriers, especially their position, in the coordinate system.

[0013] According to one possible embodiment of the method, the positions and / or orientations of the contact carriers on the carrier board image and the sequence of their assembly with the individual wires are optimized depending on the assembly parameters in the simulation such that the number of contact carriers on the carrier board image is maximized. This allows at least a large part of a wiring harness to be produced or the entire wiring harness to be assembled in a real assembly process on the carrier board. This minimizes the manufacturing time of the wiring harness and the manufacturing effort.

[0014] According to another possible embodiment of the method, the respective path of the individual lines is determined as a mathematical curve in the coordinate system, depending on the length of the individual lines and the positions of the contacts with which the individual lines are electrically contacted. Using such a curve, the path can be reliably mapped in the coordinate system in order to map the exact geometric relationships between the individual lines and the contacts of the contact carriers.

[0015] According to another possible embodiment of the method, the obstruction of an unequipped contact is determined when the curve describing the course of the individual line has a coordinate in the coordinate system at which the unequipped contact is located. This makes obstruction particularly easy and reliable to determine.

[0016] According to another possible embodiment of the method, the material properties of the individual lines and / or the paths of the individual lines in an exit area of ​​the individual lines from a contact are taken into account when determining the curves. This makes it possible to determine a correct arc length for the corresponding curve.

[0017] According to another possible embodiment of the method, the curve progressions are represented in the simulation as a static representation of an envelope curve. This allows all possible curve progressions to be statistically considered. This is necessary because a single line can only be described ideally in the form of a single curve.

[0018] According to a further possible embodiment of the method, the curves are represented in the simulation as - mathematical quadratic function, - mathematical function of a catenary or - a mathematical function describing the respective course of a curve is assumed. Using such mathematical functions, the courses of the curves can be depicted with sufficient precision, simplicity, and high reliability.

[0019] According to another possible embodiment of the method, the diameters of the individual lines are represented in the simulation as an envelope curve. This enables an accurate, reliable, and simple representation of the diameters.

[0020] The method for equipping contact carriers with individual electrical lines is characterized according to the invention in that - the contact carriers are arranged on a carrier plate according to the positions and / or orientations optimized in the simulation in the method according to one of the preceding claims, and - are automatically fitted with the individual lines in accordance with the fitting sequence optimised in the simulation in the method according to one of the preceding claims.

[0021] Due to the optimized combination of the positioning and alignment of the contact carriers on the carrier plate and the assembly sequence of the individual lines in these contact carriers, which was already determined in advance in the simulation, the actual assembly of the contact carriers with the individual lines can be carried out automatically in a simple and reliable manner.

[0022] Embodiments of the invention are explained in more detail below with reference to drawings.

[0023] Showing: Fig. 1 schematically shows a plan view of a carrier plate with several contact carriers and Fig. 2 schematically shows a plan view of the carrier plate according to Fig. 1, whereby the contact carriers are partly equipped with individual lines.

[0024] Corresponding parts are provided with the same reference numerals in all figures.

[0025] In Fig. 1 shows a plan view of a carrier plate 1 with several contact carriers 2 to 14. Fig. 2 shows a top view of the carrier plate 1 according to Fig. 1, whereby the contact carriers 2 to 14 are partially equipped with individual lines L1 to Ln.

[0026] The contact carriers 2 to 14 each have a plurality of electrical contacts K1 to K4, for example contact terminals, which are designed to electrically contact stripped, for example crimped, ends of the individual lines L1 to Ln. For example, the ends of the individual lines are connected to the contacts K1 to K4 by plugging them in.

[0027] The contact carriers 2 to 13 are each part of a plug 15 to 17 and are pre-assembled together and fastened to the carrier plate 1. The contact carrier 14 is arranged individually on the carrier plate 1, but can also be part of a plug (not shown in detail).

[0028] To equip the contact carriers 2 to 14 with the individual lines L1 to Ln, the carrier plate 1 is positioned vertically, for example.

[0029] For example, the contact carriers 2 to 14 are fitted according to the illustrated embodiment in such a way that the individual line L2 is first inserted with its ends into the contact K4 of the contact carrier 5 and into the contact K1 of the contact carrier 8.

[0030] The ends of the individual cable L1 are then inserted into contact K3 of contact carrier 3 and into contact K1 of contact carrier 6.

[0031] The ends of the individual cable Ln are then inserted into contact K1 of contact carrier 4 and into contact K3 of contact carrier 7.

[0032] This is problematic if a plugged-in individual cable L1 to Ln covers one or more free contacts K1 to K4 of contact carriers 2 to 14 that are still to be equipped with individual cables L1 to Ln. This means that no further individual cables L1 to Ln can be plugged into these contacts K1 to K4. This is the case here for contact K3 of contact carrier 9, contact K1 of contact carrier 10, and contact K1 of contact carrier 12, which are covered by the individual cable Ln.

[0033] In order to fully automate the assembly of contact carriers 2 to 14, such obstructions must be avoided. To achieve this, a simulation is used to determine an optimized assembly sequence of contact carriers 2 to 14 with individual electrical lines L1 to Ln, as well as the number, positions, and orientations of contact carriers 2 to 14 on a virtual image of carrier plate 1.

[0034] For this purpose, the dimensions of the corresponding carrier plate 1 are first determined and specified as assembly parameters. Subsequently, the number of contact carriers 2 to 14 to be electrically connected to the individual lines L1 to Ln, as well as their respective dimensions and arrangements of the electrical contacts K1 to K4 formed in or on the contact carriers 2 to 14, are determined and specified as further assembly parameters. Furthermore, the number of individual lines L1 to Ln to be electrically connected to the contact carriers 2 to 14, as well as their respective lengths, are determined and specified as assembly parameters.

[0035] To perform the simulation, a coordinate system is also generated whose x, y, and z axes extend along a longitudinal direction, a transverse direction, and a vertical direction of a virtual image of the carrier plate 1. Based on the dimensions and geometric data of the contact carriers 2 to 14 or the connectors 15 to 17 with the contact carriers 2 to 14, these can be clearly located in the coordinate system on the image of the carrier plate 1. Thus, a developer or an algorithm can now locate the corresponding contact carriers to be placed on the image of the carrier plate 1.

[0036] Subsequently, in the simulation, an arrangement of contact carriers 2 to 14 on the image of carrier plate 1 and an assembly of contact carriers 2 to 14 with individual lines L1 to Ln are simulated in the coordinate system. The number, positions, and orientations of contact carriers 2 to 14 on the image of carrier plate 1 and the assembly sequence of these with individual lines L1 to Ln are now optimized in the simulation depending on the assembly parameters in such a way that the obscuration of unassembled contacts K1 to K4 caused by individual lines L1 to Ln is minimized. Furthermore, the number of contact carriers 2 to 14 on the image of carrier plate 1 can be maximized in the simulation.

[0037] In the simulation, for each individual line L1 to Ln, it is known which line end must be plugged into which contact K1 to K4. The length of each individual line L1 to Ln is also known. This means that for each individual line L1 to Ln, two points and the length of a curve spanning between these points—i.e., an arc length—are known.

[0038] For the course of the respective curve, for example, quadratic functions, mathematical functions of a catenary line or a mathematical function describing the course of the curve can be assumed.

[0039] Accordingly, a correct course of the curve of each individual line L1 to Ln can be determined based on its material properties or a corresponding course of the curve is assumed.

[0040] In this case, it is also taken into account that the respective course of a section of the corresponding individual line L1 to Ln emerging from the contact K1 to K4 must be subtracted from its length or calculated accordingly in order to be able to determine the correct length of the curve describing the individual line L1 to Ln between the two points, i.e. between the corresponding contacts.

[0041] Furthermore, it is possible to display a diameter of the respective individual line L1 to Ln as an envelope curve.

[0042] One possible design also provides for the curve progressions to be represented statistically as an envelope curve, in order to statistically account for all possible curve progressions. This is necessary because a single line L1 to Ln can only be described ideally in the form of a single curve.

[0043] As a result, it is now possible to check all coordinates of the not yet populated contacts K1 to K4 to determine whether they are obscured by an already plugged single line L1 to Ln. Obscuration of an unpopulated contact K1 to K4 is determined if a curve describing the course of a single line L1 to Ln has a coordinate in the coordinate system at which the unpopulated contact K1 to K4 is located.

[0044] An algorithm performing the simulation now determines an optimized assembly sequence based on information determined in the simulation, since the simulation can determine which individual lines L1 to Ln must be plugged in first and which individual lines L1 to Ln must be plugged in afterwards in order not to cover any contacts K1 to K4 that have not yet been plugged in. List of reference symbols 1 carrier plate 2 to 14 contact carriers 15 to 17 plugs K1 to K4 Contact L1 to Ln single line x, y, z axis QUOTES CONTAINED IN THE DESCRIPTION

[0000] This list of documents submitted by the applicant was generated automatically and is included solely for the convenience of the reader. This list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions. Cited patent literature

[0000] DE 10 2004 055 898 A1

[0004]

Claims

[1] Method for determining an assembly sequence of contact carriers (2 to 14) with individual electrical lines (L1 to Ln), characterized by that in a simulation of an assembly of contact carriers (2 to 14) with individual electrical lines (L1 to Ln) as assembly parameters - dimensions of a carrier plate (1) intended for fastening several contact carriers (2 to 14) are determined and / or specified, - a number of contact carriers (2 to 14) to be electrically connected to the individual lines (L1 to Ln) as well as their respective dimensions and arrangements of electrical contacts (K1 to K4) formed in or on the contact carriers (2 to 14) and intended for electrical contact with the individual lines (L1 to Ln) are determined and / or specified, and - a number of individual lines (L1 to Ln) to be electrically connected to the contact carriers (2 to 14) as well as their respective lengths are determined and / or specified, in the simulation further - a coordinate system is generated whose axes (x, y, z) extend along a longitudinal direction, a transverse direction and a vertical direction of a virtual image of the carrier plate (1), - in the coordinate system, an arrangement of the contact carriers (2 to 14) on the image of the carrier plate (1) and an assembly of the contact carriers (2 to 14) with the individual lines (L1 to Ln) are simulated and - Positions and / or alignments of the contact carriers (2 to 14) on the image of the carrier plate (1) and the assembly sequence of these with the individual lines (L1 to Ln) are optimized depending on the assembly parameters in the simulation in such a way that concealments of unpopulated contacts (K1 to K4) caused by individual lines (L1 to Ln) are minimized. [2] Method according to claim 1, characterized by that positions and / or alignments of the contact carriers (2 to 14) on the image of the carrier plate (1) and the assembly sequence of these with the individual lines (L1 to Ln) are optimized depending on the assembly parameters in the simulation such that a number of contact carriers (2 to 14) on the image of the carrier plate (1) is maximized. [3] Method according to claim 1 or 2, characterized bythat depending on the length of the individual lines (L1 to Ln) and positions of the contacts (K1 to K4) with which the individual lines (L1 to Ln) are each electrically contacted, a respective course of the individual lines (L1 to Ln) is determined as a mathematical curve in the coordinate system. [4] Method according to claim 3, characterized by that a concealment of an unequipped contact (K1 to K4) is determined when the curve describing the course of the individual line (L1 to Ln) has a coordinate in the coordinate system at which the unequipped contact (K1 to K4) is located. [5] Method according to claim 3 or 4, characterized by , that in determining the curves - Material properties of the individual lines (L1 to Ln) and / or - Courses of the individual lines (L1 to Ln) in an exit area of these from a contact (K1 to K4) be taken into account. [6] Method according to one of claims 3 to 5, characterized by that in the simulation the curves are each shown as a static representation of an envelope curve. [7] Method according to one of claims 3 to 6, characterized by that in the simulation the curves are shown as - mathematical quadratic function, - mathematical function of a catenary or - a mathematical function describing the respective course of a curve can be assumed. [8] Method according to one of the preceding claims, characterized by that in the simulation the diameters of the individual lines (L1 to Ln) are each represented as an envelope curve. [9] Method for equipping contact carriers (2 to 14) with individual electrical lines (L1 to Ln), characterized by , that - the contact carriers (2 to 14) are arranged on a carrier plate (1) according to the positions and / or orientations optimized in the simulation in the method according to one of the preceding claims, and - are automatically fitted with the individual lines (L1 to Ln) in accordance with the fitting sequence optimised in the simulation in the method according to one of the preceding claims.

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