Apparatus and method for manufacturing wire harness

Abstract

A device (1) for manufacturing a cable harness comprises a presentation plate (2) on which cables (4) of the cable harness can be arranged on a front surface of the presentation plate, and handling elements (5, 5', 5") for handling the cables (4) of the cable harness. The handling elements (5, 5', 5") are magnetically attached to the presentation plate (2). The device (1) includes a pneumatic system with which an air cushion can be generated between the handling element (5, 5', 5") and the presentation plate (2), which is designed as a perforated plate. The handling elements (5, 5', 5") each comprise a front handling part (7) and a rear traversing part (8).

Description

[0001] The invention relates to a device and method for producing a cable harness.

[0002] Cable harnesses, such as those used in automobiles or aircraft, consist of multiple cables, each of which is typically equipped with connector housings at its pre-assembled cable end. A cable harness is an arrangement of multiple cables in which the cables are assembled into a structure with an often complex, branched geometry, similar to a tree.

[0003] Conventionally, these processing steps are performed on a wiring board by hand or with appropriate power tools. The entire wiring harness is stretched across the board. Workers must remove the wiring harness nodes from the board's forked holders in order to process these areas correctly.

[0004] A manually operated cable laying board is described, for example, in US 10,923,250 B2. Cable holding elements can be attached to a presentation board using suction cups. This handling element has an elongated handle with which the operator grasps the handling element and places it in the desired location. The cable holding elements can be inserted via perforated arms connected to the base part with the suction cup. Furthermore, a presentation board with blind holes predefined slots into which the cable holding elements can be directly inserted has also become known. The document contains a note stating that instead of suction cups, the handling elements could also be magnetically attached to the presentation board.

[0005] EP 2 672 490 A2 shows a generically comparable device with a horizontal display panel on which handling elements with U-shaped guides, into which cables can be placed, are magnetically attached. A base part, rectangular in plan view and equipped with magnets, is connected to the U-shaped guide part. Furthermore, a flat friction element is arranged on the base part to prevent slippage. The handling element is difficult to handle and cannot easily be relocated to another location on the display panel. A further problem is that it is only suitable for manual operation.

[0006] It is therefore an object of the present invention to avoid the disadvantages of the known and in particular to provide an improved device for producing a wiring harness which can be operated efficiently.

[0007] This object is achieved according to the invention with a device having the features of claim 1. The device for producing a wiring harness comprises a presentation plate on which cables of the wiring harness of the presentation plate can be arranged, and handling elements for handling the cables of the wiring harness. It may be necessary that certain points and areas of the wiring harness must be secured during production of a wiring harness. For example, branches and nodes can be secured using suitable aids (e.g. spot tapes or cable ties). It may also be necessary to provide the wiring harness entirely or in certain areas with additional protection (e.g., bandaging with adhesive tape). Furthermore, it may be necessary at defined points to equip the wiring harness with assembly elements such as clips in order to ultimately be able to install the wiring harness in a device intended for this purpose, such as an automobile.The processing of the cable harness mentioned above is also known to experts as “shaping” or “fixing”, since the tree-like structure is created from the multitude of individual cables.

[0008] The purpose of the presentation plate is, among other things, to present cables or cable strands of the wiring harness on this plate so that the cables or cable strands can be secured or bandaged manually or mechanically at the designated points. A handling element is understood below to be an element with which an individual cable or multiple cables are handled so that it or they can be processed with a view to manufacturing the wiring harness. Such processing could, for example, be securing certain points and areas of the wiring harness using suitable aids (e.g. spot tapes, cable ties). The presentation plate can be aligned vertically. Instead of the vertical presentation plate, a horizontal presentation plate or other orientations such as angled presentation plates would also be conceivable.

[0009] The handling elements are magnetically attached or attachable to the display plate and are preferably designed to be movable in all directions within the plane defined by the display plate. Magnetic attachment has the advantage that the position of the handling element can be reliably secured on the display plate, while simultaneously allowing the position of the handling element to be changed quickly and easily. Because the device features pneumatics, which can generate an air cushion between the handling element and the display plate, the handling elements can be moved efficiently on the display plate.

[0010] To create the air cushion between the handling element and the presentation plate, the presentation plate can be designed to be pneumatically actuated. The presentation plate can be pneumatically actuated actively or passively. In the case of an actively pneumatically actuated presentation plate, the presentation plate can, for example, have evenly distributed and preferably individually controllable air nozzles on its upper surface that blow air out in such a way that an air cushion is created in the area of ​​the handling element. In this case, the pneumatics are assigned to the presentation plate. However, the pneumatics can also be assigned to the handling elements (passive actuation of the presentation plate).

[0011] If required, and in particular to move the handling element magnetically attached to the presentation plate, the pneumatics can be activated by appropriate control, whereupon the advantageous air cushion is formed between the handling element and the presentation plate by means of the pneumatics.

[0012] For certain applications, it can be advantageous if the pneumatic system is designed to reinforce the adhesion of the handling element to the presentation plate using a vacuum, if necessary. This significantly increases the variability and application possibilities.

[0013] For pneumatic application, the display plate can be designed as a perforated plate. This perforated plate has a plurality of holes, preferably distributed throughout the display plate, through which compressed air can be passed to create the air cushion between the handling element and the display plate. The holes are therefore preferably designed as through holes, allowing compressed air to flow from the front of the display plate to the back of the display plate (and, of course, vice versa). In this way, two air cushions, i.e., one air cushion in the front area and one air cushion on the opposite side (back), can form on the display plate after the pneumatic system is activated.

[0014] The handling elements can each comprise a front-side handling part and a rear-side moving part, wherein the handling part and the associated moving part are attached to the intermediate presentation plate by means of magnets, preferably by means of permanent magnets, in such a way that the handling part can be moved along with the moving part. During this movement of the handling element on the presentation plate, the air cushion reduces the friction between the moving part and the presentation plate on the one hand, and between the handling part and the presentation plate on the other, whereby the movement can be accomplished easily and, in particular, without great expenditure of force. The device is evidently designed such that two air cushions or one air cushion with two partial cushion segments can be generated per handling element using the pneumatic system.

[0015] Dividing the handling element into a front-facing handling section and a rear-facing moving section offers significant advantages. Such a two-part handling element, with a front-facing handling section and a rear-facing moving section, can be easily and reliably mounted on the display panel and can be precisely positioned on the display panel. The front-facing handling section, facing the cable harness, is used to actually handle individual parts of the cable harness and includes means for grasping, holding together, or otherwise handling cables, for example, in the form of cable bundles, prefabricated cable ends equipped with connector housings, branches, etc. The moving section, located at the rear of the display panel, is used to move the handling element.In other words, the handling element can be moved manually or mechanically via the moving part. When the moving part moves on the presentation plate, the handling part moves congruently with it. This separation ensures efficient and trouble-free operation, as the moving elements required for handling and movement do not interfere with each other. Automation of the system is also easily possible thanks to this separation. Intermediate designs are also conceivable, in which the movement is performed automatically and at least certain work on the cable harness at the front is performed manually.

[0016] For magnetic attachment, the perforated plate-shaped presentation plate can preferably be made of a non-ferromagnetic material. If the handling elements each comprise a front-side handling part and a rear-side moving part, at least one of the parts of the respective handling element can be equipped with a permanent magnet for magnetic attachment to the presentation plate, with the other part containing ferromagnetic material or the other part also being equipped with a permanent magnet, so that the permanent magnets attract each other.

[0017] Permanent magnets can be used to magnetically attach the handling elements to the preferably vertical display panel. These magnets can be used to securely hold the handling elements in the desired position on the display panel. Preferably, permanent magnets (e.g., neodymium magnets) are selected to prevent accidental detachment of the handling elements from the display panel, even under heavy loads. However, it can also be advantageous to select permanent magnets that are strong enough to allow the handling elements to be easily replaced by hand if necessary. The replacement process could also be supported by pneumatics.

[0018] Permanent magnets have the advantage that they ensure reliable operation in a simple manner and, in particular, remain in the current position on the presentation plate in the event of a fault (e.g. an unexpected power failure due to a mains failure).

[0019] In a preferred embodiment, the aforementioned vertical display panel, on which cables of the cable harness can be arranged on a front side of the display panel, can be made of a non-ferromagnetic material. The handling elements or the respective handling elements can each comprise a front-side handling part and a rear-side moving part, wherein at least one of the parts (ieHandling part, moving part) of the respective handling element is equipped with a permanent magnet for magnetic attachment to the presentation plate and wherein the other part contains ferromagnetic material or the other part is also equipped with a permanent magnet, but with an opposite pole, so that the permanent magnets attract each other (handling part and moving part roughly correspond therefore: 1 permanent magnet and 1 ferromagnetic material; or 2 permanent magnets with opposite poles, so that the permanent magnets attract each other). The latter case with the two permanent magnets is to be understood in such a way that the permanent magnets are arranged and oriented in such a way that opposite poles are opposite each other, so that the permanent magnets attract each other.

[0020] The respective handling element can have at least one chamber open towards the presentation plate. If a handling part and a movement part are present as described above, the front-side handling part, on the one hand, and the rear-side movement part, on the other hand, preferably each have a chamber open towards the presentation plate. Thanks to the chamber, a stable and reliable air cushion can be created, so that the handling part can be advantageously moved on the presentation plate. A supporting edge can delimit the respective chamber to the outside. This supporting edge can run in the direction of the plate and thus, in the case of a vertical plate, run horizontally. The supporting edge can preferably be circular.

[0021] The moving part can have a coupling part connected to a sliding part. A sliding part is understood to be a part facing the presentation plate, which is in contact with the presentation plate and slides along the presentation plate when moved. Thanks to the air cushion, the sliding occurs almost frictionlessly. The permanent magnet is preferably integrated into the sliding part. However, the sliding part could also consist of or contain ferromagnetic material. The sliding part can be assigned the above-mentioned support edge, which edge contacts the surface of the presentation plate and is supported or can be supported. The coupling part, on the other hand, is a part facing away from the presentation plate.

[0022] The handling part can have a handling head connected to a sliding part. Preferably, the two sliding parts of the moving part and the handling part are designed identically. The sliding part of the handling part can be designed approximately the same as the base body of the moving part, particularly with regard to its dimensions and in particular with regard to its base area. The permanent magnet is preferably integrated into the sliding part. However, the sliding part could also consist of or contain ferromagnetic material. The above-mentioned support edge can be assigned to the sliding part.

[0023] The sliding part itself can be constructed in two parts. The two-part sliding part can comprise a front sliding part relative to the display plate and a base body (as the rear part). The sliding part and base body can be made of different materials. For example, the sliding part can be made of plastic and the base body a metal component.

[0024] To seal the chamber from the outside, the support edge can be designed as a flexible rubber seal. It may be advantageous if an elastomer sealing lip is provided or arranged on the support edge.

[0025] The respective handling element, in particular the moving part of the handling element, can have a pneumatic connection via which compressed air can be fed into the handling element or, if necessary, the vacuum can be generated.

[0026] The device can have a positioning system for moving the handling elements into the desired position, which is preferably integrated into the presentation plate. The integrated positioning system is formed in particular by a gantry robot. The positioning system for moving the handling element comprises a positioning head with a coupling part for mechanical coupling, via which the positioning system can be brought into mechanical operative connection with a respective handling element. A pneumatic coupling part is integrated in the coupling part, which is preferably designed as a lance complementary to the pneumatic connection of the handling element. By means of gantry robots, the handling elements can be moved quickly and precisely into the desired position. If necessary, even complex distances can be easily covered when moving using the gantry robot.As an alternative to the gantry robot, delta robots or other types of positioning robots or positioning systems are also conceivable.

[0027] The positioning system can comprise a positioning head with several coupling parts for moving several handling elements, via which the positioning system can be mechanically connected (i.e., coupled) to one or more handling elements, so that the movement of the positioning head can then be transmitted to the handling element. The coupling parts can be movable separately or jointly relative to one another, at least with respect to the plane of the presentation plate. These several coupling parts can be rigidly connected to one another. However, it can be advantageous if the several coupling parts can be moved separately relative to one another, at least with respect to the plane of the presentation plate, thereby enabling even more complex movements.

[0028] In a preferred embodiment, the moving part of the handling element can be a coupling part with a spherical outer contour for the mechanical coupling, wherein the outer contour has a flattened spherical shape. Within the coupling part, an insertion opening sealed or sealable by an O-ring can be arranged for the pneumatic coupling to create the pneumatic connection, into which, for example, the lance is inserted or can be inserted.

[0029] A further embodiment relates to a device in which at least some of the handling elements are designed as housing holders for holding housings. In this case, the respective housing holder can temporarily hold a single housing or, under certain circumstances, even several housings for the production of the cable harness. A housing, the purpose of which is in particular to create electrical plug connections, or more precisely the prefabricated cable end provided with the housing, can be moved into the desired position on the presentation plate thanks to the housing holder. The housing holder can have a housing receptacle, into which the housing(s) can be inserted for secure holding, or other means for temporarily holding the housing. The housing receptacle is assigned to the handling head of the housing holder.

[0030] Alternatively or additionally, at least some of the handling elements can be designed as deflectors for redirecting the routing of cables. If the housing holders are considered the first type of handling element, the deflectors for redirecting the routing of cables of the cable harness (one or, if necessary, several cables can be redirected, whereby in the case of several cables, the cables are usually present as a loose or already secured cable bundle) form a second type of handling element. Deflectors are used, for example, to bend individual cables at defined positions, for example, at branches, in the branched structure of the cable harness.

[0031] Alternatively or additionally, at least some of the handling elements can be designed as hold-ups. The hold-ups form a third type of handling element. Hold-ups serve to hold up individual cables or multiple cables combined in the form of a cable harness, thus increasing the distance to the presentation plate to allow cables to be passed underneath the aforementioned individual cable or cables held upright. By means of one and preferably two hold-ups, for example, a main strand of the cable harness can be held further away from the positioning plate in a section, creating an enlarged gap beneath the cable harness held up in this way, allowing other parts of the cable harness to be guided underneath without obstruction, for example by means of a housing holder, thereby enabling further branching on two sides.

[0032] A further aspect of the invention relates to a device for producing a cable harness, in particular the device described above, which is characterized in that a handling part attached or attachable to a presentation plate has a handling head connected to a sliding part, which is preferably rotatably connected to the sliding part with respect to a normal direction predetermined by the presentation plate, wherein the bearing for the rotatable connection between the handling head and the sliding part has a locking mechanism for securing the handling head in a desired rotational position (secured position). The normal direction is understood to mean a direction running at right angles to the plane of the presentation plate. The axis of rotation of the handling head connected to the sliding part in a rotatable manner in the normal direction can thus be a horizontal axis of rotation in the case of a vertical presentation plate.

[0033] Preferably, the locking mechanism is operatively connected to the pneumatics to generate the air cushion between the handling element and the presentation plate, so that by means of the pneumatics, after appropriate control of the pneumatics, the rotation lock can be removed by the locking mechanism and the handling head is freely rotatably connected to the sliding part.

[0034] The device can then comprise a processing robot, with the aid of which securing means can be attached to the cables for fixing and securing them point by point or in sections. This processing robot, designed, for example, as an articulated-arm robot, can be arranged in the area of ​​the rear side of the presentation panel. In contrast to the preferred positioning system, the processing robot is usually separate. It can be permanently connected to the floor or designed to move autonomously across the floor.

[0035] In terms of the method, the invention is characterized in that (i) cables equipped with housings and required for the cable harness are arranged on a display plate using housing holders and other handling elements, the handling elements being magnetically attached to the display plate, and (ii) the handling elements are moved on the display plate by pneumatically introducing compressed air into the handling element(s) to be moved, thereby creating an air cushion between the handling element and the display plate. This method for producing a cable harness can be carried out in particular using the device described above.

[0036] If the handling elements each comprise a front-side handling part and a rear-side moving part, the respective handling element can be magnetically attached to the display plate, whereby the handling part and moving part attract each other and thus adhere together to the display plate. With magnetic attachment, the intermediate display plate is, in a sense, clamped between the handling part and the associated moving part by means of or under the action of the magnetic force. In other words, the attractive forces of the magnets associated with the handling part on the one hand and the moving part on the other cause the intermediate display plate to be clamped.

[0037] At least one of the parts of the respective handling element can be equipped with a permanent magnet for magnetic attachment to the presentation plate, wherein the other part contains ferromagnetic material or the other part is also equipped with a permanent magnet, so that the permanent magnets attract each other.

[0038] The handling elements can be moved in individual steps. It can be advantageous if, after completing a single-step movement of the handling element, the compressed air supply is first disconnected from the handling element and then, after the separation has taken place, the mechanical coupling of the handling element to a positioning system for moving the handling element to the desired position is removed. The two steps of disconnecting the compressed air supply and removing the mechanical coupling can occur very quickly one after the other.

[0039] If the handling element needs to be held to the presentation plate with increased adhesion, a vacuum can be created between the handling element and the presentation plate. This allows the handling element to be temporarily fixed securely and virtually immovably to the presentation plate.

[0040] Further individual features and advantages of the invention will become apparent from the following description of exemplary embodiments and from the drawings. They show: Figure 1 shows a perspective view of a device according to the invention for producing a cable harness with a presentation plate and a plurality of handling elements mounted thereon (presentation plate seen from the front), Figure 2 shows the device from Figure 1in a perspective view from a different viewing direction (presentation plate seen from the back), Figure 3 a perspective, enlarged view of the presentation plate and three types of handling elements (housing holder, deflector, holder) for the device according to Figure 1 , Figure 4 a perspective view of a positioning head with several coupling parts for moving handling elements and a handling element designed as a housing holder, Figure 5a a top view of a presentation plate with a moving part of a handling element lying thereon, Figure 5b the presentation plate in an alternative embodiment, Figure 6 a side view with a broken view of a handling element designed as a housing holder and attached to the presentation plate of the device according to the invention, Figure 7 the handling element from Figure 6with the coupling part of the positioning system coupled to it at a slight angle, Figure 8 shows the handling element with the coupling part of the positioning system coupled straight, the handling element being in a position in which the locking mechanism for its handling head against rotation to a sliding part is released, Figure 9 shows a perspective, enlarged illustration of the presentation plate and the handling element designed as a housing holder with the handling head rotatably connected to the sliding part, Figure 10 shows a plan view of components of an alternative presentation plate for the device according to the invention for producing a cable harness.

[0041] Figure 1shows a device 1 for producing a cable harness. Cable harnesses, such as those used in automobiles or aircraft, consist of several cables, each of which is usually provided with connector housings at its pre-assembled cable end. A cable harness is an arrangement of several cables or lines in which these are joined together to form a structure with an often complex, branched geometry similar to a tree. The respective cable is usually an electrical cable containing, for example, a solid conductor made of copper or aluminum or wire strands and insulation as a sheath for the conductors. The term "cable" is to be understood broadly below. In the present case, a cable is also understood to mean, for example, a cable unit made up of several cables or lines of equal length combined into a unit, such as a twisted cable harness.

[0042] In addition to the Figure 1 In addition to the device 1 shown, the system can further comprise a cable processing machine and a housing assembly machine (not shown here), which can be located upstream of the device 1. The cable processing machine can comprise a stripping station known per se for cutting and stripping the cables, one or more crimping stations for applying crimp contacts to the stripped cable ends, and optionally one or more grommet stations. In the housing assembly machine, the connector housings are fitted with pre-assembled cable ends from the cable processing machine.

[0043] After wiring, cable harnesses must be prepared for their intended use so that they can then be installed in the devices intended for them, such as automobiles. The cables required for the respective cable harness, which were assembled in the cable processing machine and housing assembly machine mentioned above, for example, are assembled into a tree-like structure using device 1, which is described in detail below. Branches and junctions must be secured using suitable securing devices (e.g., spot tape or cable ties). The cable harness may also need to be provided with additional protection, either entirely or in sections (e.g., by bandaging with durable adhesive tape).

[0044] The device 1 for producing a cable harness comprises a vertical display plate 2, on which cables of the cable harness can be arranged on a front side of the display plate 2. The cables designated 4, which are already pre-assembled and equipped with housings, are arranged in a Figure 1 shown intermediate position in the form of more or less freely hanging loops on the presentation plate 2. The housings of the cables 4 are held by housing holders 5. In Figure 1 Two further types of handling elements can be seen, namely deflectors marked 5' and high holders marked 5". These handling elements are located in a waiting position in parking zones at the edge of the presentation plate 2. These handling elements wait until they are used for the production of a cable harness, if necessary.

[0045] The device 1 further comprises a processing robot 40 in the area of ​​the rear side of the presentation plate 2, with the aid of which securing means for fixing and securing the cables 4 at specific points or in sections can be attached. For example, spot tapes can be applied with the processing robot 40. In this case, the processing robot 40 is designed as an articulated-arm robot. The articulated-arm robot can be rigidly connected to the floor or can be designed to move autonomously on the floor.

[0046] As can be seen from the rear view of the presentation plate 2 according to Figure 2 As can be seen, the handling elements 5, 5', 5" can be moved by means of a gantry robot on the presentation plate in all directions of the plane defined by the presentation plate 2.

[0047] The presentation plate 2 is preferably made of a non-ferromagnetic material. The presentation plate 2 can be made of stainless steel, for example. However, other metallic plates made of non-ferromagnetic material are also suitable for the presentation plate. The presentation plate 2 could also be made of plastic.

[0048] Each of the handling elements 5, 5', 5" comprises a front-side handling part 7 and a rear-side travel part (8, see Figure 2), wherein the handling part 7 and the moving part are each equipped with a permanent magnet for magnetic attachment to the presentation plate, so that the permanent magnets attract each other. For this purpose, the permanent magnets are arranged and oriented in such a way that opposite poles face each other, whereby the permanent magnets attract each other. When the moving part is moved on the presentation plate, the handling part is moved along with it. One permanent magnet can be provided for each part (handling part, moving part); however, several permanent magnets could also be provided for each part and would be advantageous.

[0049] The attractive forces of the magnets clamp the intermediate presentation plate 2. This ensures that the handling elements 5, 5', 5" remain in their position on the vertically aligned presentation plate 2.

[0050] To temporarily reduce the static friction of the handling elements 5, 5', 5" on both sides of the presentation plate 2, the presentation plate 2 is provided with a hole pattern, and the positioning system 3 is equipped with a compressed air supply. For this purpose, the device 1 has a pneumatic system with which an air cushion can be generated between the handling element 5, 5', 5" and the presentation plate 2. The two parts of the handling elements 5, 5', 5" (coupling part and handling part) each have a chamber to create an air cushion. Thanks to the air cushion, the strong adhesive forces resulting from the permanent magnets can be reduced, allowing the handling elements 5, 5', 5" to be moved easily and effortlessly on the presentation plate 2. A compressor 20 is indicated in the figures as a compressed air source for operating the pneumatic system. The compressed air source is integrated into the device 1 in this case.The compressed air source, such as a compressor or another compressed air source, could of course also be located externally. A compressed air supply line is also conceivable for providing the compressed air.

[0051] Since the clamping force of the magnets must be sufficiently high, especially for larger cable harnesses, so that the handling elements 5, 5', 5" can maintain their position despite the additional weight on the presentation plate 2, the magnets are designed to be correspondingly strong. Thanks to pneumatics, comparatively simple positioning systems can be used that do not need to be particularly powerful or robust, since the air cushion eliminates the need to overcome the high static friction generated by clamping with the magnets.

[0052] Figure 2shows the device 1 with a rear view of the presentation plate 20. Here, the moving parts are visible and designated by 8. In the present case, the moving parts 8 are designed essentially identically for all types of handling elements 5, 5', 5".

[0053] The moving parts 8 are responsible for the movement of the handling elements 5, 5', 5". To move the handling elements into the desired position, the device 1 has a positioning system 3. The positioning system 3, integrated in the presentation plate 2, is formed in this case by a gantry robot. The positioning system 3 or the gantry robot has a beam-like gantry carriage that can be moved back and forth in the x-direction along linear guides and a second carriage equipped with a positioning head 31 that can be moved back and forth in the y-direction along the gantry carriage, transverse to the x-direction. The positioning head 31 of the gantry robot forms, in a sense, the interface to the handling element. The positioning head 31 can grasp the handling element via coupling means and move it to the desired location through the controlled movement of the gantry robot.For this purpose, the positioning head 31 has at least one coupling part which can be brought into engagement with a coupling part of the handling element for movement.

[0054] Figure 3shows the three different types of handling elements: housing holder 5, deflector 5', and high holder 5". The handling elements differ essentially in the different design of the front-side handling part; the rear-side moving parts are designed approximately the same for all handling elements. The handling part 7 of the housing holder 5 has a handling head 19, which is rotatably connected to a sliding part 18. The housing holder 5 has means for temporarily holding the housing, for example a housing receptacle, into which the housing can be inserted for secure holding. The handling part of the deflector 5' and the high holder 5" have sliding parts that are designed similarly to the sliding part 18 of the housing holder 5, at least with regard to external shape and dimensions. The difference lies primarily in the different design of the respective handling heads.The handling part of the deflector 5' evidently has a handling head with a hook. The handling part of the holder 5" has a handling head with a U-shaped cable receiving section in which cables are collected and loosely held together, wherein the cable receiving section is further away from the display panel 2 for holding the cable up.

[0055] The handling part of the deflector 5' can comprise a handling head connected to a sliding part, which is fixedly or preferably freely rotatably connected to the sliding part. When the deflector is attached to the presentation plate 2, the axis of rotation runs relative to the normal direction (z-direction) defined by the presentation plate 2. The handling head of the deflector 5' is designed such that, when the deflector 5' is attached to the presentation plate 2, it remains in its vertically aligned basic position due to gravity. The same applies to the 5" holder. The 5" holder also has a handling head 19" connected to a sliding part, which is freely rotatably connected to the sliding part 18. The handling head 19" of the 5" holder is designed such that, when the 5" holder is attached to the presentation plate 2, it remains in its vertically aligned basic position due to gravity.

[0056] The handling elements 5, 5', 5" are mounted on a presentation plate 2 designed as a perforated plate and made of a non-ferromagnetic material, which perforated plate has a plurality of through holes 6 evenly distributed on the presentation plate, through which holes 6 compressed air can be passed to generate the air cushion between the handling element 5, 5', 5" and the presentation plate 2.

[0057] The operation of the pneumatics of device 1 is explained below using the Figures 4 to 8 explained. Figure 4 relates to a perspective view of a positioning head 31 with several coupling parts for moving handling elements and a handling element 5 designed as a housing holder, wherein the handling element 5 is aligned in such a way that its coupling part 17 is more clearly visible for a better understanding of the interface.

[0058] The positioning head 31 associated with the gantry robot of the positioning system 3 has several coupling parts 32. In the present case, the positioning head 31 has, for example, four coupling parts 32. Four handling elements can be moved simultaneously via the coupling parts 32. Figure 4 The coupling part 32, which is the frontmost one from the observer's perspective, is in an extended position, in which coupling would be possible. The remaining three coupling parts are in a rest position. In this position, only one handling element could be moved with the positioning system 3. If necessary, however, additional or different coupling parts could also be extended to create an active position, whereupon two or more handling elements can be moved. Of course, it is conceivable to equip the positioning head 31 of the positioning system 3 with only one such coupling part 32.

[0059] The respective coupling part 32 is designed as a bushing for the mechanical coupling. A pneumatic coupling part designed as a lance 33 is integrated into the coupling part. The lance 33 is clearly arranged centrally in the cavity of the coupling part 32.

[0060] The coupling parts 32 are mounted relative to the positioning head 31 in a normal direction defined by the presentation plate 2. Reference numeral 35 denotes a compressed air supply line for the pneumatic system, which supplies compressed air to a lance 33. Reference numeral 34 denotes a pneumatic actuator, with the aid of which the coupling part 32 can be extended from the rest position to the active position. The coupling parts can be preloaded in the rest position, for example, by means of springs (not shown).

[0061] Each of the coupling parts 32, which can be extended by means of pneumatic actuators 34, has plate-like segments 36, each of which contains a sealed transverse bore (not shown) for conducting compressed air from the compressed air supply line 35 to the lance 33. The compressed air supply line 35 is a rigid tube with a seal to accommodate the movement during extension and retraction. The actuator 34 comprises a piston rod running coaxially with the lance.

[0062] The handling element 5 consists, as shown in Figure 4 can be removed, from the front handling part 7 and the rear moving part 8. Not shown in Figure 4the presentation plate 2. However, a indicates a distance or space between the handling part 7 and the rear-side moving part 8, which distance corresponds to the thickness of the presentation plate 2. The presentation plate, not shown here, is contacted by sliding parts 14, 18 of the handling part 7. The sliding part 14 is a component of the coupling part 17 of the handling element 5 and is thus assigned to the moving part 8; the sliding part 18 is assigned to the handling part 7.

[0063] The coupling part 17 of the handling element 5 has a spherical outer contour for the mechanical coupling, with a flattened portion 22 of the spherical shape. The spherical shape serves to compensate for slight angular errors between the presentation plate and the positioning system. The flattened portion prevents the handling element from rotating when moved on the presentation plate.

[0064] If a specific handling element is to be moved, the positioning head 31 is moved to the handling element by means of the gantry robot, and then the coupling part 32 is extended. When the coupling part 32 is extended, the coupling part 32 comes into contact with the coupling part 17 assigned to the handling element. The coupling process is now complete, and the handling element can now be moved. Before the movement begins, however, the pneumatic system is activated and compressed air is fed into the handling element. An air cushion forms between the handling element and the presentation plate; the handling element can now be moved on the presentation plate with virtually no friction.

[0065] Figure 5a shows a hole pattern of the presentation plate 2. The holes 6 form a kind of perforated sieve structure and are arranged at equal intervals in a straight grid on the presentation plate 2. 11 is Figure 5aFurther shown is a supporting edge of a sliding piece of the handling element 5. This sliding piece can be assigned to either the handling part or the moving part, since the respective sliding pieces of both elements (handling element, moving part) are designed essentially identically.

[0066] Figure 5b shows a variant for a hole pattern of the presentation plate 2. In this hole pattern, the holes 6 are arranged alternately offset from one another in rows, forming the triangle indicated by dashed lines.

[0067] The hole pattern can be square ( Figure 5a ) or triangular ( Figure 5b). In the preferred embodiments, a hole 6 must always be located within the air chamber area of ​​the handling element, or in other words, at least the total area of ​​a hole 6 must always be within the chamber area in order to ensure a continuous travel plane during the movement of the handling element on the presentation plate. Furthermore, the sizes of the holes, which are round in the present example, are advantageously selected such that the hole diameter d is smaller than the thickness D of the support edge 11 of the handling elements.

[0068] Construction details for the structure of the handling element 5 are shown in the Figures 6 and 7 removable. A housing holder is shown here. The structure of other handling elements, such as deflectors and hold-down devices, is fundamentally the same, except for the handling heads. Figure 6shows a handling element 5, magnetically attached to the presentation plate 2 and designed, for example, as a housing holder. One or more permanent magnets, designated 9 and 10 in the present case, are inserted into the handling part 7 on the one hand and the movement part 8 on the other hand of the handling element 5. The respective parts each have corresponding receptacles in the sliding parts 14, 18, into which the permanent magnets 9, 10 are inserted. The sliding parts are constructed identically and differ essentially only in the polarity of the magnets inserted therein. The sliding part 14, 18 itself is constructed in two parts and consists of a front sliding piece 15 with respect to the presentation plate 2 and a base body 16 as the rear part. The sliding piece 15 is preferably made of plastic, the base body 16 of metal.The handling part 7 of the handling element 5 has a chamber 13 open toward the presentation plate 2, while the moving part 8, on the other hand, each has a chamber 12 open toward the presentation plate 2. The supporting edge 11 delimits the respective chamber 12, 13 to the outside.

[0069] The moving part 8 has a pneumatic connection through which the compressed air can be fed into the handling element 5. For this purpose, an insertion opening 23, which can be sealed by means of an O-ring 24 and into which the lance (not shown here) can be inserted, is arranged within the coupling part 17.

[0070] In Figure 7 , in the opposite Figure 6the broken view is slightly adapted, it is shown that after coupling, the coupling part 32 assigned to the positioning system 3 could still be connected to the coupling part 17, even in a slightly tilted position, due to the inherently undesirable inaccurate positioning of the positioning head. The mechanical coupling of the handling element 5 is spherical with a flattened portion in order to be able to compensate for slight angular errors between the presentation plate 2 and the positioning system 3. In the normal or longitudinal direction of the lance, sufficient play is provided before and after the O-ring 24 in order to be able to compensate for the angular errors between the presentation plate and the positioning system. Therefore, the compressed air coupling and the mechanical coupling are preferably coordinated with one another so that the center of the sphere and the sealing O-ring 24 are at the same height.

[0071] The handling element 5 is thus equipped with a compressed air coupling in order to receive the compressed air, to be able to direct it to the first chamber 12, through the presentation plate 2 and to the second chamber 13.

[0072] A further advantage of the device 1 is that, if necessary, when the handling element 5 is to be held with increased adhesion to the presentation plate 2, a vacuum is generated between the handling element 5 and the presentation plate 2. Thus, the pneumatic system can operate the handling element 5 in two different states: a state in which compressed air creates the air cushion for movement and a state in which the vacuum holds the handling element to the presentation plate with particularly high holding force.

[0073] Thanks to this design, a vacuum can also be temporarily created in the chambers via the positioning system 3. The vacuum increases the forces absorbed by the handling elements 5, making the processing of the cable branches of the wiring harness more resilient. The vacuum can be provided either via a compressed air supply line or generated using a Venturi nozzle.

[0074] The handling elements 5 can be moved in individual steps. After the movement step, the positioning system first disconnects the compressed air supply and then the mechanical connection to the handling element. Otherwise, an undesirable sagging of the handling element 5 attached to the vertical display plate 2 may occur. The two steps of disconnecting the compressed air supply and removing the mechanical coupling can occur very quickly one after the other.

[0075] As previously described, compressed air can be fed from the compressed air supply line 35 to the lance 33 via a transverse bore in the plate-like segment 36. However, other designs are also conceivable, such as a version without the separate line 35. For example, the compressed air for extending the coupling part 32 can flow through a taper in the form of an orifice through the piston rod of the pneumatic actuator 34 into the lance 33 and further into the handling element 5, where the air cushion is built up. After the target position has been reached, the compressed air can be switched such that no new air is fed through the piston rod, which would cause the air cushion to collapse. To do this, the piston rod is pushed back with the redirected air. Since the coupling and the lance allow a certain stroke without loss of contact, the handling part is still guided for a short time during the backward movement.

[0076] According to a further embodiment, elastomer sealing lips (not shown) can be installed around the chambers to increase the efficiency of either the air cushion or, if necessary, a vacuum. These sealing lips could be molded onto the slider 15 in the area of ​​the support edge 11 or attached to it.

[0077] Figure 8 , in which, compared to the Figures 6 and 7 The broken view is adjusted again, shows a variant of a handling element 5, in which the bearing between the sliding part 18 and the handling head 19 has a special anti-rotation device. Here - in comparison to Figure 7 - the coupling part 32 assigned to the positioning system 3 is connected to the coupling part 17 of the handling element 5 in the normally occurring normal coupling position.

[0078] When presenting the branches of the cable harness, situations can arise in which the cable branch and the handling head 19 of the handling element 5 are only aligned with each other under considerable tensile force (e.g., horizontal alignment). If further tensile forces are applied during the processing of the branches (e.g., bandaging), the handling element 5 must be designed accordingly large to be able to absorb all forces. Therefore, in the Figure 8 In the embodiment shown, the handling element 5, which is designed in particular as a housing holder, is supplemented with a locking mechanism which can be decoupled by means of the supplied compressed air.

[0079] The handling element 5, designed as a housing holder and mounted on the presentation plate 2, has a handling head 19 connected to a sliding part 18, which is rotatably connected to the sliding part 18 with respect to the normal direction. The bearing for the rotatable connection between the handling head 19 and the sliding part 18 has a locking mechanism 25 for securing the handling head in a desired rotational position (locked position). The locking mechanism is operatively connected to the pneumatic system, so that, after appropriate control, the anti-rotation lock created by the locking mechanism 25 can be removed by means of the pneumatic system, and the handling head 19 is freely rotatably connected to the sliding part 18.

[0080] The locking mechanism 25 serves to determine the orientation of the handling head 19. The supplied compressed air disengages the locking mechanism 25, allowing the handling head 19 to rotate freely according to the tensile forces of the cable branch. The locking mechanism 25 can, for example, have a pitch of 45° or more (90°, 120°, or 180°).

[0081] The locking mechanism 25 comprises a locking crown 26 arranged at the end of a piston 27, into which locking cams 29 assigned to the handling head 19 engage or can engage in a locking manner. A piston rod 28, for example, with a square cross-section, is also visible. To release the rotation lock provided by the locking connection, compressed air is fed into the piston chamber after appropriate control, and the spring-loaded piston 27 is displaced in the e-direction, whereby the locking crown 26 is moved away from the locking cams 29 to such an extent that the locking connection is released, thus resulting in the free rotation of the handling head 19. Figure 8 shows the locking mechanism in a position in which it is disengaged.

[0082] Thanks to this locking mechanism 25, the handling head 19 can be pulled into the desired angular position and held in place, even though the tension on the branch of the cable harness has been reduced. This also has the advantage that the handling elements 5 can be made smaller.

[0083] The decoupling of the locking mechanism 25 can be carried out both together with the construction of the air cushion with a common operating pressure or independently of it (by means of two operating pressures).

[0084] Figure 9 shows the handling element 5 designed as a cable holder housing holder with the handling head 19 rotatably connected to the sliding part 18. The handling head 19 can be rotated from the vertically aligned basic position shown, for example, by 45° about the rotation axis designated S. Thanks to the locking mechanism 25, the handling head 19 can be pulled into the desired angular position and held in the angular position indicated by dashed lines.

[0085] The Figure 3 The presentation plate 2 shown, designed as a simple perforated plate, is passively pneumatically pressurized. The pneumatics are assigned to the handling elements 5. However, versions of presentation plates that are actively pneumatically pressurized are also conceivable. Such an actively pneumatically pressurized presentation plate, or its main components, is shown in Figure 10shown. 39 denotes an outer plate designed as a perforated plate. 38 denotes an intermediate plate 38. The presentation plate is a composite component with two outer plates 39 and an intermediate plate 38 arranged between them. The plates 38, 39 can be connected to one another, for example, by gluing. The intermediate plate 38 has channel-like recesses 41 that extend from the edge to ends that lead to the holes 6 after assembly. In this way, the individual holes 6 can be supplied with compressed air from the edge, for example controlled via valves (not shown). An alternative actively pneumatically actuated presentation plate can, for example, have evenly distributed and preferably individually controllable air nozzles on its upper side, which blow out air in such a way that an air cushion is created in the area of ​​the handling element.

Claims

1. Device (1) for producing a cable harness comprising a presentation plate (2) on which cables (4) of the cable harness can be arranged on a front side of the presentation plate, handling elements (5, 5', 5") for handling the cables (4) of the cable harness, wherein the handling elements (5, 5', 5") are magnetically attached or attachable to the presentation plate (2), characterized in that the device (1) has a pneumatic system with which an air cushion can be generated between the handling element (5, 5', 5") and the presentation plate (2).

2. Device (1) according to claim 1, characterized in that the presentation plate (2) is designed to be pneumatically actuated.

3. Device (1) according to claim 1 or 2, characterized in that the pneumatic system is designed to reinforce the adhesion of the handling element (5, 5', 5") to the presentation plate (2) by means of a vacuum, if required.

4. Device (1) according to one of claims 1 to 3, characterized in thatthe handling elements (5, 5', 5") each comprise a front-side handling part (7) and a rear-side travel part (8).

5. Device (1) according to one of claims 4 to 6, characterized in that the presentation plate (2) is designed as a perforated plate, which perforated plate has a plurality of holes (6) through which compressed air can be passed.

6. Device (1) according to claim 4 or 5, characterized in that the handling part (7) on the one hand and the rear moving part (8) on the other hand each have a chamber (12, 13) open towards the presentation plate (2).

7. Device (1) according to claim 6, characterized in that a sealing lip is provided on a supporting edge (11) to seal the respective chamber.

8. Device (1) according to one of claims 1 to 7, characterized in thatthe respective handling element (5, 5', 5"), in particular the moving part (8) of the handling element (5, 5', 5"), has a pneumatic connection via which compressed air can be fed in.

9. Device (1) according to one of claims 1 to 8, characterized in that it has a positioning system (30) for moving the handling elements (5, 5', 5") into the desired position, wherein the positioning system for moving the handling element (5, 5', 5") comprises a positioning head (31) with a coupling part (32) for mechanical coupling, and that a pneumatic coupling part, preferably designed as a lance (33), is integrated in the coupling part (32).

10. Device (1) according to claim 8 or 9, characterized in thatthe movement part (8) of the handling element (5, 5', 5") has a coupling part (17) with a spherical outer contour for the mechanical coupling, wherein the outer contour has a flattening (22) of the spherical shape, and that an insertion opening (23) sealed or sealable by means of an O-ring (24) is arranged within the coupling part (17).

11. Device (1) in particular according to one of claims 1 to 10, characterized in that a handling part (7) mounted or mountable on a presentation plate (2) has a handling head (19) adjoining a sliding part (18) which is rotatably connected to the sliding part (18), wherein the bearing for the rotatable connection between the handling head (19) and the sliding part (18) has a locking mechanism (25) for securing the handling head in a desired rotational position.

12. Device (1) according to claim 11, characterized in thatthe locking mechanism is operatively connected to the pneumatic system, so that the rotation lock by the locking mechanism (25) can be removed by means of the pneumatic system and the handling head (19) can rotate freely.

13. A method for producing a cable harness, in particular using the device (1) according to one of claims 1 to 12, wherein - cables (4) equipped with housings and required for the cable harness are arranged on a presentation plate (2) using handling elements (5, 5', 5"), wherein the handling elements (5, 5', 5") are magnetically attached to the presentation plate (2), - the handling elements (5, 5', 5") are moved on the presentation plate (2) by introducing compressed air, whereby an air cushion is generated between the handling element (5, 5', 5") and the presentation plate (2).

14. Method according to claim 13, characterized in thatafter completion of a single-step movement of the handling element (5, 5', 5"), the compressed air supply is first disconnected from the handling element (5, 5', 5") and then the mechanical coupling of the handling element (5, 5', 5") is released.

15. Method according to claim 13 or 14, characterized in that If, if necessary, the handling element (5, 5', 5") must be held with increased adhesion to the presentation plate (2), a vacuum is created between the handling element (5, 5', 5") and the presentation plate (2).

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