Device and method for compiling a dataset for the manufacture and installation of a wiring harness
Patent Information
- Application Number
- EP2023764638
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2022-09-05
- Filing Date
- 2023-09-01
- Publication Date
- 2025-07-16
AI Technical Summary
The production and assembly of complex electrical cable sets in vehicle technology remain partially automated due to the need for diverse data formats and models, which are often generated manually and incompletely digital, hindering efficient automation.
A device and method that create a unified data set using virtual 3D models of cable set components and systems, enabling automated production and assembly by merging proprietary data models through an ontology module for semantic networking, ensuring consistent data models and information flow, and allowing for automated manufacturing and assembly without manual calibration.
This solution enables efficient, automated production and assembly of cable sets with improved process and manufacturing quality, reducing the need for manual intervention and ensuring a consistent data model, thereby optimizing the production and assembly processes.
Smart Images
Figure 1.1
Abstract
Description
[0001] Device and method for creating a data set for the production and assembly of a wiring harness
[0002] The present invention relates to the manufacture and assembly of electrical wiring harnesses. In particular, the invention relates to devices, methods, and a system for creating a data set for the automated manufacture of a wiring harness for a vehicle and for the automated assembly of the wiring harness in the vehicle.
[0003] Cable harnesses (also known as wire harnesses) are used in numerous products and industries to connect electrical components, for example, so that the electrical components can be supplied with power and / or communicate with each other. Particularly in automotive engineering, sometimes complex cable harnesses are installed as components of on-board electrical systems in motor vehicles, aircraft, trains, and the like. Such cable harnesses can be highly complex, particularly with numerous cables, connectors, retaining devices for mounting in the vehicle, and the like.
[0004] To date, the production and assembly of wiring harnesses has only been partially automated, if at all. This is primarily due to the fact that different data may be required for different sub-processes of production and assembly. For example, product data such as 3D geometry data of the wiring harness and / or the wiring harness components, process data such as processing steps of a wire in the wiring harness, and resource data such as information about the equipment used to create and / or assemble the wiring harness are used. This data is often still generated manually and cannot be digitally stored, is only available in an incomplete form, and / or in different formats or data models. Therefore, it has not yet been used to automate the production and assembly of a wiring harness.The task is therefore to realize a device, a method and a system in order to efficiently determine and provide a data set for the essentially automated production and assembly of a wiring harness.
[0005] This object is achieved by the features of the independent patent claims. Advantageous embodiments are the subject of the figures, the description, and the dependent patent claims.
[0006] According to a first aspect, the invention relates to a device for creating a data set for a production system for the automated production of a wiring harness for a vehicle and for an assembly system for the automated assembly of the wiring harness in the vehicle. The wiring harness comprises a plurality of wiring harness components. The plurality of power pack components can, in particular, comprise a plurality of plug connectors, a plurality of electrical lines for connecting the plurality of plug connectors, a plurality of housing receptacles, and / or a plurality of holding devices. A plug connector can, for example, have an electrical contact part that can be surrounded by a plug connector housing, in particular made of plastic.
[0007] The device comprises a processor device configured to create the data set based on virtual 3D models of the plurality of wiring harness components of the wiring harness and a virtual 3D model of the wiring harness. In other words, the processor device is configured to merge the virtual 3D models of the plurality of wiring harness components and the virtual 3D model of the wiring harness into a single data set.
[0008] The device further comprises a communication interface which is designed to provide the data set to the production plant, in particular to a control device of the production plant, and to the assembly plant, in particular to a control device of the assembly plant.
[0009] The data set comprises first data configured such that the production system automatically manufactures the wiring harness based on the first data. The data set further comprises second data configured such that the assembly system automatically assembles or installs the wiring harness in the vehicle based on the second data. This makes it possible for the data set to be used for both automated production and automated assembly of the wiring harness. Furthermore, the wiring harness can be represented using a consistent data model, ensuring a consistent flow of information. This allows, for example, the process quality and manufacturing quality of the wiring harness to be efficiently monitored and optimized.
[0010] For the automated production of the wiring harness, the production facility may, for example, comprise at least one automated machine or robot. The at least one automated machine of the production facility may, for example, comprise a placement machine and / or a winding machine, which is controlled in particular by the control device of the production facility.
[0011] For automated assembly of the wiring harness, the assembly system can, for example, comprise at least one automated assembly machine or assembly robot for assembly, i.e., for installing the wiring harness in the vehicle. The at least one automated assembly machine of the assembly system can be controlled, in particular, by the control device of the assembly system.
[0012] The data set can be generated, for example, based on product data and / or process data of the wiring harness, which can be transmitted, for example, from the assembly system, in particular the control device of the assembly system, to the communication interface. Furthermore, the data set can be generated, for example, based on resource data of the production system, which can be transmitted, for example, from the production system, in particular the control device of the production system, to the communication interface.
[0013] The product data can, for example, include information about the position of a housing surrounding the wiring harness to be manufactured, in particular a 3D geometry. The product data can also include, for example, information about the chamber assignments of the wiring harness to be manufactured. Chambers can be part of the housing and correspond to predefined spaces that accommodate and retain a contact part and wires of the wiring harness.
[0014] The process data can include, for example, information about the plug-in widths, plug-in depths, and plug-in heights of the wires to be plugged into the wiring harness. Furthermore, the process data can include, for example, information about a counter-tension test and / or processing of the wiring harness, in particular through cutting, crimping, and / or soldering processes performed by the production system.
[0015] The resource data may, for example, include information about supported assembly pallets, available tools and information about one or more machines in the production plant, in particular the assembly machine and / or a winding machine.
[0016] According to one embodiment, the processor device is configured to generate the second data based on the first data or to semantically link the second data with the first data. The processor device can be configured to implement an ontology module configured to generate the second data based on the first data or to semantically link the second data with the first data.
[0017] Using the ontology module, a semantic link, in particular a network, can be established between all the different proprietary data models of, for example, individual units of a vehicle manufacturer's production facility and / or assembly facility. This enables a continuous exchange of information between all proprietary data models without the need to provide individual interfaces at the system level. Rather, the semantic networking achieved with the ontology module enables the data models to be mapped into a comprehensive digital model, a so-called digital twin, which enables a bidirectional, harmonized data flow between all units of the production facility and all units of the assembly facility without additional hardware effort at the system level.In particular, completely different proprietary data models from the areas of product development, manufacturing and assembly can be networked.
[0018] For example, the ontology module can specify class structures that form ontologies, which have classes structured hierarchically or in assemblies, by means of which a semantic networking of the proprietary data models can be implemented. Advantageously, the classification is carried out using metamodels structured in ontology libraries. These ontologies advantageously allow the semantic networking of the proprietary data models to be configured. This allows for flexible data mapping of all proprietary data models. According to one embodiment, the first data defines a reference position of the wiring harness and the positions and / or orientations of the plurality of wiring harness components relative to the reference position of the wiring harness.
[0019] According to one embodiment, the second data define a reference position of the vehicle and the position and / or orientation of the wiring harness relative to the reference position of the vehicle.
[0020] This allows the vehicle manufacturer's assembly plant to efficiently install the wiring harness into the vehicle, for example, making calibration of an automatic machine in the assembly plant no longer necessary.
[0021] According to one embodiment, the first data and / or the second data define one or more process parameters of the manufacturing plant and / or the assembly plant.
[0022] For example, the one or more process parameters can include parameters for the manufacturing process of the wiring harness by the at least one automated machine of the production plant, in particular the pick-and-place machine and / or the winding machine. For example, the one or more process parameters can include parameters for the assembly process of the wiring harness by the automated machine of the assembly plant.
[0023] According to one embodiment, the communication interface is designed to provide the data set to the manufacturing plant and / or the assembly plant via a communication network or to store the data set on a portable data carrier and to provide the portable data carrier to the manufacturing plant and / or the assembly plant.
[0024] Depending on the requirements, the data set can thus be transmitted to the production plant and / or the assembly plant particularly securely and / or without delay.
[0025] The portable data storage device can, for example, be a mechanically lockable data storage device, in particular a USB stick. The communication network can, for example, be implemented via a cloud server, which in particular implements a cloud application. According to a second aspect, the invention relates to a system for manufacturing a wiring harness for a vehicle and for assembling the wiring harness in the vehicle. The system comprises a device according to the first aspect for creating a data set, a manufacturing system for the automated production of a wiring harness based on the data set, and an assembly system for the automated assembly of the wiring harness in the vehicle.
[0026] According to a third aspect, the invention relates to a method for creating a data set for a manufacturing system for the automated production of a wiring harness for a vehicle and for an assembly system for the automated assembly of the wiring harness in the vehicle, wherein the wiring harness comprises a plurality of wiring harness components.The method comprises creating the data set based on virtual 3D models of the plurality of wiring harness components of the wiring harness and a virtual 3D model of the wiring harness and providing the data set to the manufacturing plant and to the assembly plant, wherein the data set comprises first data which are designed such that the manufacturing plant automatically manufactures the wiring harness based on the first data, and wherein the data set comprises second data which are designed such that the assembly plant automatically assembles or installs the wiring harness in the vehicle based on the second data.
[0027] The embodiments mentioned for the subject matter of the first aspect are also embodiments for the subject matter of the second aspect and the third aspect.
[0028] Further advantages and details of the invention are explained in more detail using the exemplary embodiments illustrated in the schematic figures. Herein:
[0029] Fig. 1 shows a block diagram of a system according to an embodiment for manufacturing a wiring harness for a vehicle and for assembling the wiring harness in the vehicle;
[0030] Fig. 2 schematically shows an exemplary wiring harness; and Fig. 3 shows a flowchart of a method according to an embodiment for creating a data set for a manufacturing plant for manufacturing a wiring harness for a vehicle and for an assembly plant for assembling the wiring harness in the vehicle.
[0031] The figures are merely schematic representations and serve only to illustrate the invention. Identical or equivalent elements are provided with the same reference numerals throughout.
[0032] Figure 1 shows a schematic block diagram of a system 100 for manufacturing a wiring harness 140 for a vehicle 180, in particular a passenger car 180, and for assembling the wiring harness in the vehicle 180. As those skilled in the art will recognize, the components of the system 100 described below do not necessarily have to be used at a common production facility, but can also be operated remotely from one another. Some or all of the components of the system 100 described below can be connected to one another or to a central device 110 via a communications network 150 to enable communication among themselves or with the central device 110.The device 110 is configured to create a data set 117 for a manufacturing facility 120, 130 for the automated production of the wiring harness 140 for the vehicle 180 and for an assembly facility 160, 170 for the automated assembly of the wiring harness 140 in the vehicle 180. The communication network 150 can comprise a local communication network, such as a corporate network, and / or a global communication network, such as the Internet. The manufacturing facility 120, 130 is configured for the automated production of the wiring harness 140 based on the data set 117, and the assembly facility 160, 170 is configured for the automated assembly of the wiring harness 140 in the vehicle 180 based on the data set 117.
[0033] Figure 1 shows the device 110, which can communicate with a control device 120 of the production plant 120, 130 and with a control device 160 of the assembly plant 160, 170 of a vehicle manufacturer 190 (also referred to as OEM 190). For this purpose, the device 110 comprises a communication interface 113. The device 110 further comprises a processor device 111 and may comprise a non-volatile memory 115. The non-volatile memory 115 may be configured to store data and executable program code which, when executed by the processor device 111 of the device 110, causes the processor device 111 to perform the functions, operations, and methods described below.
[0034] Even if this is not shown in Figure 1, the control device 120 of the production system 120, 130 and the control device 160 of the assembly system 160, 170 can also have communication interfaces for communication and processors and memories for data processing.
[0035] The processor device 111 of the apparatus 110 is configured to create the data set 117 based on virtual 3D models of a plurality of wiring harness components of the wiring harness 140 and a virtual 3D model of the wiring harness 140. In other words, the processor device 111 is configured to merge the virtual 3D models of the plurality of wiring harness components of the wiring harness 140 and the virtual 3D model of the wiring harness 140. As shown in more detail in Figure 2, the plurality of wiring harness components of the wiring harness 140 can, in particular, comprise a plurality of plug connectors 141a-c, 142a-c, a plurality of electrical lines 143a-c for connecting the plurality of plug connectors 141a-c, 142a-c, a plurality of housing receptacles, and / or a plurality of holding devices 145a,b.
[0036] The communication interface 113 of the device 110 is designed to provide the data set 117 to the production system 120, 130, in particular to the control device 120 of the production system, and to the assembly system 160, 170, in particular to the control device 160 of the assembly system.
[0037] Data set 117 includes first data configured such that the production system 120, 130 automatically manufactures the wiring harness 140 based on the first data. Data set 117 further includes second data configured such that the assembly system 160, 170 automatically assembles or installs the wiring harness 140 in the vehicle 180 based on the second data.
[0038] The data set 117 can be generated, for example, based on product data and / or process data of the cable harness 140, which can be transmitted, for example, from the assembly system 160, 170, in particular the control device 160 of the assembly system 160, 170, to the communication interface 113. Furthermore, the data set 117 can be generated, for example, based on resource data of the production system 120, 130, which can be transmitted, for example, from the production system 120, 130, in particular the control device 120 of the production system 120, 130, to the
[0039] Communication interface 113 can be transmitted.
[0040] The product data can, for example, include information about a housing position of a housing surrounding the cable harness 140 to be manufactured, in particular a 3D geometry. The product data can further include, for example, information about chamber assignments of the cable harness 140 to be manufactured. Chambers can be part of the housing and correspond to predefined spaces that accommodate and retain a contact part and the electrical lines 143a-c of the cable harness 140.
[0041] The process data can include, for example, information about the plug-in widths, plug-in depths, and plug-in heights of the electrical cables 143a-c to be plugged into the cable harness 140. Furthermore, the process data can include, for example, information about a counter-tension test and / or processing of the power set 140, in particular cutting, crimping, soldering, and / or additional winding processes that can be performed by the production system 120, 130.
[0042] The processor device 111, in particular an ontology module implemented by the processor device 111, can be configured to generate the second data based on the first data or to semantically link the second data with the first data. The ontology module can, in particular, further be configured to semantically link the second data with the first data and / or to semantically link the product data, the process data, and the resource data.
[0043] Using the ontology module, a semantic network of all the various proprietary data models of, for example, individual units of the production facility 120, 130 and / or the assembly facility 160, 170 of the vehicle manufacturer 190 can be established. This enables a continuous exchange of information between all proprietary data models without the need to provide individual interfaces at the system level. Rather, the semantic networking achieved with the ontology module enables a mapping of the data models in a comprehensive digital model, a so-called digital twin, which enables a bidirectional, harmonized data flow between all units of the production facility 120, 130 and the assembly facility 160, 170 of the vehicle manufacturer 190 without additional hardware effort at the system level.In particular, completely different proprietary data models from the areas of product development, manufacturing and assembly can be networked.
[0044] For example, the ontology module can contain class structures that form ontologies, which have classes structured hierarchically or in assemblies, by means of which a semantic networking of the proprietary data models can be implemented. Advantageously, the classification is carried out using metamodels structured in ontology libraries. These ontologies advantageously allow the semantic networking of the proprietary data models to be configured. This enables flexible data mapping of all proprietary data models. Further details of the ontology module according to a preferred embodiment can be found in DE 10 2019 128 104 A1, which is hereby incorporated by reference.
[0045] The first data can define a reference position of the wiring harness 140 and the positions and / or orientations of the plurality of wiring harness components relative to the reference position of the wiring harness 140. Furthermore, the second data can define a reference position of the vehicle 180 and the position and / or orientation of the wiring harness 140 relative to the reference position of the vehicle 180. Furthermore, the first data and / or the second data can define one or more process parameters of the manufacturing facility 120, 130 and / or the assembly facility 160, 170.
[0046] The communication interface 113 can be designed to provide the data set 117 to the production plant 120, 130 and / or the assembly plant 160, 170 via the communication network 150 or to store the data set 117 on a portable data carrier and to provide the portable data carrier to the production plant 120, 130 and / or the assembly plant 160, 170.
[0047] The control device 120 of the production system 120, 130 can be configured to receive the data set 117 and to control the at least one automatic placement machine 130 of the production system 120, 130. The production system 120, 130, in particular the at least one automatic placement machine 130, can be configured to manufacture the wire harness 140 based on the data set 117. In addition to the control device 120 and the automatic placement machine 130, the production system 120, 130 can further comprise an automatic winding machine that bandages the wire harness 140 after partial production by the automatic placement machine 130.In one embodiment, the control device 120 of the manufacturing plant 120, 130 can be configured to transmit the resource data to the device 110, which can include, for example, information about supported assembly pallets, available tools and information about the pick and place machine(s) 130 of the manufacturing plant 120, 130.
[0048] The control device 160 of the assembly system 160, 170 of the vehicle manufacturer 190 can be designed to control an assembly of the wiring harness 140 in a vehicle 180, in particular a passenger car 180, by an automatic machine or assembly robot 170 of the assembly system 160, 170 based on the data set 117.
[0049] The central device 110 can be configured to control the production of the wiring harness 140 based on the resource data from the control device 120 of the production system 120, 130 as well as the product data and the process data from the control device 160 of the assembly system 160, 170. For this purpose, the central device 110 can be configured to transmit the data set 117 to the control device 120 of the production system 120, 130, which can define production work steps, for example, executable program code for the at least one automatic pick-and-place machine 130 of the production system 120, 130, and / or production components.
[0050] In a further embodiment, the device 100, which may be embodied, for example, as an industrial PC 100, may further comprise a display device not shown in Figure 1. The display device may, for example, be configured to display the virtual 3D models of the plurality of wiring harness components of the wiring harness 140 and / or the virtual 3D model of the wiring harness 140.
[0051] Figure 2 shows a schematic representation of the wiring harness 140 produced based on the data set 117. The data set 117 can cause the placement machine 130 of the production system 120, 130, or instruct a user of the placement machine 130, to first mount so-called receiving devices at defined positions on the placement pallet and then to insert identical or different connectors 141 ac, 142a-c into the individual receiving devices. The placement machine 130 can then be configured to connect the electrical lines 143a-c to the connectors 141a-c, 142a-c. The connectors 141 ac, 142a-c can have a number of pins and / or contact parts corresponding to the number of electrical lines 143a-c or a number different therefrom.
[0052] Furthermore, the manufacturing system 120, 130 may include one or more additional units and / or devices (not shown), such as, for example, a device for cutting the electrical leads 143a-c, a device for attaching electrical contact parts, and / or a crimping machine. In a further embodiment, these additional units and / or devices may also be integrated into the placement machine 130.
[0053] The electrical lines 143a-c connected to the connectors 141a-c, 142a-c can then be removed from the assembly pallet and laid out on a construction board (also referred to as an assembly aid), particularly manually or automatically. The electrical lines 143a-c can then be further processed. This can include wrapping at least some sections of the electrical lines 143a-c (also referred to as bandaging) with a material by the automatic winding machine in order to bundle several electrical lines 143a-c.
[0054] In a further embodiment, the electrical lines 143a-c can alternatively and / or additionally be further processed on the assembly pallet, in particular at least partially wrapped or bandaged with a material by the winding machine in order to bundle a plurality of electrical lines 143a-c.
[0055] Furthermore, holding devices 145a-b can be attached at specific positions of the electrical lines 143a-c. The holding devices 145a-b can, in particular, be configured differently, for example, as a support for the electrical lines 143a-c and / or as a holder for the connectors 141a-c, 142a-c. In this way, based on the data set 117, a wiring harness 140 with a defined 3D structure is created, which can be installed in the vehicle 180.
[0056] Figure 3 shows a flowchart of a method 300 for creating the data set 117 for the production system 120, 130 for the automated production of the wiring harness 140 for the vehicle 180 and for the assembly system 160, 170 for the automated assembly of the wiring harness 140 in the vehicle 180. The method 300 comprises a step 301 of creating the data set 117 based on virtual 3D models of the plurality of wiring harness components of the wiring harness 140 and a virtual 3D model of the wiring harness 140.The method 300 further comprises a step 303 of providing the data set 117 to the production plant 120, 130 and to the assembly plant 160, 170, wherein the data set 117 comprises first data which are designed such that the production plant 120, 130 automatically manufactures the wiring harness 140 on the basis of the first data, and wherein the data set 117 comprises second data which are designed such that the assembly plant 160, 170 automatically assembles or installs the wiring harness 140 in the vehicle 180 on the basis of the second data.
[0057] List of reference symbols
[0058] 100 systems
[0059] 110 Device
[0060] 111 Processor device of the device
[0061] 113 Communication interface of the device
[0062] 115 Device memory
[0063] 117 data sets
[0064] 120, 130 production plant
[0065] 120 Control device of the production plant
[0066] 130 placement machine
[0067] 140 wiring harness
[0068] 141a-c, 142a-c connectors
[0069] 143a-c Electrical cables
[0070] 145a-b Holding device
[0071] 150 Communication network
[0072] 160, 170 assembly plant
[0073] 160 Control device of the assembly system
[0074] 170 assembly robots
[0075] 180 vehicles
[0076] 190 vehicle manufacturers
[0077] 300 Methods for Determining a Manufacturing Configuration
[0078] 301 First procedural step of the procedure
[0079] 303 Second procedural step of the procedure
Claims
Patent claims 1. A device (110) for creating a data set (117) for a manufacturing facility (120, 130) for manufacturing a wiring harness (140) for a vehicle (180) and for an assembly facility (160, 170) for assembling the wiring harness (140) in the vehicle (180), wherein the wiring harness (140) comprises a plurality of wiring harness components, the device (110) comprising: a processor device (111) configured to create the data set (117) based on virtual 3D models of the plurality of wiring harness components of the wiring harness (140) and a virtual 3D model of the wiring harness (140); and a communication interface (113) configured to provide the data set (117) to the manufacturing facility (120, 130) and the assembly facility (160, 170);wherein the data set (117) comprises first data which are designed such that the manufacturing plant (120, 130) manufactures the wiring harness (140) on the basis of the first data, and wherein the data set (117) comprises second data which are designed such that the assembly plant (160, 170) assembles the wiring harness (140) in the vehicle (180) on the basis of the second data; 2. Device (110) according to claim 1, wherein the processor device (111) is designed to generate the second data on the basis of the first data or to semantically link the second data with the first data.
3. Device (110) according to claim 2, wherein the processor device (111) is designed to implement an ontology module, and wherein the ontology module is designed to generate the second data on the basis of the first data or to semantically link the second data with the first data.
4. The device (110) according to any one of the preceding claims, wherein the first data defines a reference position of the wiring harness (140) and the positions and / or orientations of the plurality of wiring harness components relative to the reference position of the wiring harness (140).
5. Device (110) according to one of the preceding claims, wherein the second data define a reference position of the vehicle (180) and the position and / or orientation of the wiring harness (140) relative to the reference position of the vehicle (180).
6. Device (110) according to one of the preceding claims, wherein the first data and / or the second data define one or more process parameters of the manufacturing plant (120, 130) and / or the assembly plant (160, 170).
7. Device (110) according to one of the preceding claims, wherein the communication interface (113) is designed to provide the data set (117) to the production plant (120, 130) and / or the assembly plant (160, 170) via a communication network (150) or to store the data set (117) on a portable data carrier and to provide the portable data carrier to the production plant (120, 130) and / or the assembly plant (160, 170).
8. Device (110) according to one of the preceding claims, wherein the plurality of wiring harness components comprise a plurality of connectors (141a-c, 142a-c), a plurality of electrical lines (143a-c) for connecting the plurality of connectors (141a-c, 142a-c), a plurality of housing receptacles and / or a plurality of holding devices (145a,b).
9. System (100) for manufacturing a wiring harness (140) for a vehicle (180) and for assembling the wiring harness in the vehicle (180), the system (100) comprising: a device (110) according to one of the preceding claims for creating a data set (117); a production system (120, 130) for manufacturing a wiring harness (140) on the Basis of the dataset (117); and an assembly system (160, 170) for assembling the wiring harness (140) in the vehicle (180).
10. A method (300) for creating a data set (117) for a manufacturing plant (120, 130) for manufacturing a wiring harness (140) for a vehicle (180) and for an assembly plant (160, 170) for assembling the wiring harness (140) in the vehicle (180), wherein the wiring harness (140) comprises a plurality of wiring harness components, the method (300) comprising: Creating (301) the data set (117) based on virtual 3D models of the plurality of wiring harness components of the wiring harness (140) and a virtual 3D model of the wiring harness (140); and Providing (303) the data set (117) to the manufacturing plant (120, 130) and to the assembly plant (160, 170); wherein the data set (117) comprises first data configured such that the manufacturing plant (120, 130) manufactures the wiring harness (140) on the basis of the first data, and wherein the data set (117) comprises second data configured such that the assembly plant (160, 170) assembles the wiring harness (140) in the vehicle (180) on the basis of the second data.