Cable assembly and method for providing at least one first cable by means of a cable assembly

Abstract

The present invention relates to a cable arrangement (1) for providing at least one first cable (2), comprising at least one first cable (2) aligned lengthwise in a first plane (XY), and a first support structure (3) aligned in or parallel to the first plane (XY), wherein the at least one first cable (2) is fixed to the first support structure (3) by means of an adhesive, and the fixation can be released by mechanically separating the at least one first cable (2) and the first support structure (3). The present invention further relates to a method for providing at least one first cable (2) by means of a cable arrangement (1).

Description

Technical field

[0001] The invention relates to a cable arrangement and a method for providing at least one first cable by means of a cable arrangement, preferably on a production line in automated vehicle manufacturing. State of the art

[0002] Flat ribbon cables or small-diameter round cables have a ribbon-like shape with a pronounced longitudinal axis. A small diameter is preferably defined as less than 10 mm, more preferably less than 5 mm, and most preferably less than 1 mm. A flat ribbon cable typically contains a multitude of (parallel) conductors arranged along its longitudinal axis. Flat ribbon cables can be single-layered or multi-layered. A small-diameter round cable usually has only one conductor or strand. These conductors are generally suitable for power and / or data transmission. Several flat ribbon or round cables can be joined together to form a cable harness. A cable harness, by its very nature, is highly branched, depending on its configuration, to reach every component that needs to be connected to it.Due to their material properties and elongated shape, flat ribbon cables or small-diameter round cables often exhibit flexible bending behavior. This flexibility makes them suitable for routing along contours, for example, along the body of a vehicle or other contoured components.

[0003] When installing a conventional wiring harness, which (at least in sections) consists of large cable strands (with a diameter greater than 10 mm), in a vehicle, the harness is folded using a specific technique and delivered to the vehicle's assembly line in a carrying bag. On the assembly line, factory personnel unpack the harness and lay it out in the vehicle. Due to the harness's flexible nature, its position within the transport container (carrying bag) is undefined, meaning that only manual installation by factory personnel is possible in the vehicle. As mentioned previously, there is an alternative option to replace the wiring harness made of large cable strands with a flat ribbon cable harness or a harness made of small-diameter round cables.

[0004] When a flat ribbon cable, a small-diameter round cable, or a corresponding wiring harness is to be supplied on the production line for installation in a vehicle, its flexibility presents several disadvantages. A major drawback is that if a cable or wiring harness is produced, for example, on a layup board, and then removed from the flat support surface, the cable or harness components lose their position, slip relative to each other, or twist due to this flexibility. In other words, without the support of the support surface or a flat structure that defines the relative position of the individual parts (branches) of the cable or wiring harness, any defined position of the cable or harness is lost. Components without a defined position or positioning are extremely difficult to automate.However, automation on the production line is increasingly required, especially in vehicle manufacturing. Description of the invention

[0005] It is therefore an object of the present invention to provide a cable arrangement and a corresponding method with which at least one flat ribbon cable or a small diameter round cable can be provided with a defined positioning.

[0006] The aforementioned problem is solved by a cable arrangement according to claim 1 or 2 and a method for providing at least one first cable by means of a cable arrangement according to claim 9. Further advantageous embodiments of the invention can be found in the dependent claims, the description, and the drawings.

[0007] In particular, the above-mentioned problem is solved by a cable arrangement for providing at least one first cable comprising at least one first cable which is aligned lengthwise in a first plane and a first support structure which is aligned in the first plane or parallel thereto, wherein the at least one first cable is fixed to the first support structure by means of an adhesive and the fixing can be released by mechanical separation of the at least one first cable and the first support structure.

[0008] The described cable arrangement has at least the advantage of being easy to produce and, in particular, automatable. The (first) support structure provides the cable with a positioning option, prevents twisting of the cable, and prevents parts from slipping relative to one another. The adhesive is selected to ensure secure fixation of the cable to the support structure. Mechanical separation is easy and, in particular, can be automated. Essentially, mechanical separation requires only forces in different directions on the cable and the support structure. The forces involved are preferably less than those that could damage the cable. The (first) support structure is an auxiliary device that is preferably only temporarily fixed to the cable.Fixing the cable to or on the support structure essentially freezes predetermined and known positions of the cable or cable harness fixed to a support structure until the cable or cable harness is transferred to a further (assembly) process on the production line. A cable can comprise a ribbon cable or a round cable, wherein the round cable has a diameter of less than 10 mm, preferably less than 5 mm, and most preferably less than 1 mm.

[0009] The above-mentioned problem is further solved in particular by a cable arrangement for providing at least one first cable comprising at least one first cable aligned lengthwise in a first plane and a first support structure aligned in the first plane, wherein the at least one first cable is integrated into the first support structure and the support structure has a first area in which the at least one first cable runs and a second area in which no cable runs, and the first area of ​​the support structure can be separated from the second area of ​​the support structure by mechanical separation.

[0010] The present cable assembly has the advantage that the cable is manufactured together with the support structure, thus defining the cable's path on or within the support structure, while the external dimensions of the support structure are also fixed. This cable assembly can be shipped and / or further processed directly after its manufacture; for final assembly of the cable, only at least one second section needs to be separated from the first. This simplifies the transport and processing of the cable.

[0011] Preferably, the first support structure comprises a film-like element, in particular a plastic film. The cable with the film-like support structure has a thin-layer construction and is easily stackable with a high packing density. The film-like support structure can be rolled up for transport or laid flat in a transport box, such as a cardboard box, which saves space. Furthermore, due to its planar structure, the support structure has a defined outer contour when laid flat. This defined outer contour allows, for example, the gripping of defined points on the support structure using suction cups.

[0012] Preferably, the adhesive comprises a releasable adhesive or temporarily molten plastic on the first support structure and / or the at least one first cable, wherein the at least one first cable is mechanically separated by peeling it off the first support structure, or vice versa. In particular, the adhesive creates a (temporary) metallurgical bond between the support structure and the at least one first cable, wherein the adhesive may comprise a separate substance or may be produced by melting the support structure and / or the first cable. The adhesive strength of the adhesive is selected such that a cable is securely held, but the bond can also be released by peeling or pulling the components apart.If plastic is temporarily melted on the support structure and / or the cable, so that the molten plastic has an adhesive effect, the amount of molten plastic is chosen so that the cable is securely fixed, but the adhesive connection can also be released again by simple mechanical separation without leaving damage to the support structure and / or the cable.

[0013] Preferably, the first support structure has perforations along the at least one first cable, wherein the at least one first cable is mechanically separated from the first support structure by cutting through the perforations, or vice versa; or the first support structure has perforations along the first region, wherein the first region of the support structure is mechanically separated from the second region of the support structure by cutting through the perforations. The perforations provide a means of separating the support structure from the cable, and vice versa, regardless of the adhesive used.In this case, "detaching" means, in particular, that the support structure not directly connected to the cable is detached, equivalent to the second areas, from the areas of the support structure in direct contact with the cable, equivalent to the first areas, so that the areas of the support structure in direct contact with the cable can remain attached to the cable. The areas of the support structure that remain attached to the cable can be detached separately or remain permanently attached to the cable, forming an additional layer on an outer surface of the cable, with the additional layer, for example, forming insulation.

[0014] Preferably, at least one cable or the first section of the support structure has multiple optical markers that are visible in the first plane. These optical markers allow a cable to be detected, identified, and / or its position and orientation to be determined. Furthermore, the cable can be precisely located using these optical markers. Determining the position and orientation typically requires multiple (distinctive) points or optical markers. Because the cable is reliably aligned in the first plane via the (planar) support structure, all markers in the first plane can be detected, and the cable can be easily and unambiguously identified. A cable without a support structure, for example, could be twisted, so that not all or no optical markers in the first plane are visible, and the cable cannot be unambiguously identified.

[0015] Preferably, the cable arrangement further comprises at least one separate second support structure to which at least one separate second cable is attached, wherein the first and second cables can form a composite cable harness without their respective support structures. A complex cable harness can be divided into individual cables (strands) and attached to separate support structures. This division offers the advantage that different layers of the cable harness can be represented separately, and a complex cable harness can be assembled step by step. During assembly, however, several layers can also be mounted together at once. The carrier film allows all layers to be packaged, stacked, picked, and positioned in a defined manner.Furthermore, the division simplifies the handling and transport of the cable harness, as, for example, only a reduced number of gripping devices are needed for the cables compared to the number of gripping devices for the entire cable harness. Additionally, the division allows for greater flexibility in the creation of a cable harness, so that certain cables (or cable strands) can be used in different cable harnesses.

[0016] Preferably, the second support structure has the same dimensions as the first, allowing both to be arranged compactly in a transport box. This allows the transport box to be tailored to the size of the support structure, saving both material and space. Furthermore, if all support structures are identical in design and arrangement within the transport box, centering the transport box automatically centers the support structures, simplifying handling.

[0017] The above-mentioned problem is further solved in particular by a method for providing at least one first cable by means of a cable arrangement, wherein the method comprises at least the following steps: providing and aligning the at least one first cable in a first plane and a first support structure in the first plane or parallel to the first plane, providing an adhesive between the first support structure and the at least one first cable, connecting the first support structure and the at least one first cable so that the at least one first cable is fixed to the first support structure, and releasing the fixation by mechanically separating the at least one first cable and the first support structure.

[0018] The described process is simple and, in particular, can be automated. Fixing with an adhesive is technically easy to implement. Mechanical separation is also easy and can be automated.

[0019] Preferably, the method further comprises the following steps before releasing the fixation: repeating the preceding steps for at least one separate second support structure and at least one separate second cable, and arranging at least the first and separate second support structures in a transport box to save space. By fixing two separate cables to two separate support structures, they can be flexibly unpacked and used on the production line. This increases the flexibility of manufacturing and transport. The steps for fixing a cable to a support structure are always the same. Space-saving arrangement means that the (additional) arrangement of the second support structure does not require (significantly) more space than arranging (only) the first support structure, as would be the case, for example, when stacking the support structures, where the footprint always remains the same.

[0020] Preferably, the method further comprises the following steps: Before releasing the fixation, providing the transport box to a production line, and scanning and / or removing the at least one first cable with the first support structure attached to it, and upon releasing the fixation, peeling the first support structure off the at least one first cable, or vice versa, or cutting a perforation in the first support structure along the at least one first cable and positioning the at least one first cable at the production line.

[0021] Removing at least the first cable means explicitly gripping the cable. The cable has a predetermined position within the transport box, allowing for easy and predictable gripping. Once gripped in this predetermined position, the cable can be easily and reliably positioned at the production line or for further processing, particularly through automated processes. Removal can also be achieved by stripping or similar means. Removing the cable or cutting through the perforation are simple process steps that can be readily automated.

[0022] The following description of embodiments is given with reference to the accompanying figures. These show: Fig. 1 a perspective view of an embodiment of a (flat ribbon) cable arrangement; Fig. 2 an exploded view of an embodiment of several support structures, each with a (flat ribbon) cable fixed to it in a transport box; and Fig. 3 a schematic representation of another embodiment of a cable arrangement with perforations between a first and a second area of ​​the support structure.

[0023] Preferred embodiments are described in detail below with reference to the accompanying figures.

[0024] Fig. 1Figure 1 shows a preferred embodiment of a (flat ribbon) cable arrangement 1 for providing at least one first (flat ribbon) cable 2. The illustrated flat ribbon cable arrangement 1 comprises at least one first flat ribbon cable 2, in particular a first, second, and third flat ribbon cable 2, 4, 6, which is aligned lengthwise in a first plane XY, and a first support structure 3 which is aligned in the first plane XY or parallel thereto. The illustrated first, second, and third flat ribbon cables 2, 4, 6 form a composite cable harness. "Aligned parallel to" means that the first support structure 3 and the first flat ribbon cable 2 are abutting each other.

[0025] The illustrated first support structure 3 comprises a film-like element, in particular a plastic film. In alternative embodiments, the first support structure 3 can, for example, comprise a sheet of paper or cardboard. The surface of the first support structure 3 is preferably smooth and optionally coated to promote adhesion and removability of the fixation.

[0026] The illustrated at least one first ribbon cable 2 is fixed to the first support structure 3 by means of an adhesive. Generally speaking, the adhesive creates a (particularly temporary) material bond between the ribbon cable 2 and the support structure 3. The adhesive preferably comprises a releasable adhesive or temporarily melted plastic on the first support structure 3 and / or the at least one first ribbon cable 2. In one embodiment, the plastic of the first support structure 3 and / or the first ribbon cable 2 can be briefly melted by applying heat, for example with the aid of a laser or by friction welding. The melting is preferably carried out only locally, in particular at specific points, in order not to impair the overall structure of the first support structure 3 and / or the first ribbon cable 2.Before the molten plastic cools down (again), the first flat ribbon cable 2 is fixed (at least locally) to the first support structure 3.

[0027] The fixation can be released by mechanically separating the at least one first ribbon cable 2 from the first support structure 3. If the adhesive comprises a releasable adhesive, the at least one first ribbon cable 2 can be mechanically separated by peeling it off the first support structure 3, or vice versa. In alternative embodiments, peeling can include peeling or stripping. The adhesive can also form a non-releasable, material-bonded connection in alternative embodiments. In the case of, for example, a non-releasable adhesive, or as an alternative separation method for releasable connections, the first support structure 3 can have perforations along the at least one first ribbon cable 2. The perforations comprise material weakenings caused by depressions or holes in the first support structure 3.The perforations are preferably introduced into the first support structure 3 subsequently, for example by laser or punching. The at least one first ribbon cable 2 can be mechanically separated from the first support structure 3 by cutting through the perforations, or vice versa.

[0028] With reference to Fig. 2 A preferred embodiment of a ribbon cable arrangement 1 is shown, which further comprises at least one separate second support structure 5, and in particular a separate third support structure 7, to which at least one separate second ribbon cable 4 or a separate third ribbon cable 6 is fixed. The illustrated first, second, and third ribbon cables 2, 4, 6, without the respective first, second, and third support structures 3, 5, 7, can form a composite ribbon cable harness (see Figure 1). Fig. 1 and Fig. 2 ).

[0029] Fig. 3Figure 1 shows a further embodiment of a cable arrangement 100 for providing at least one first cable 102. The illustrated cable arrangement 100 has at least one first cable 102, which is aligned lengthwise in a first plane XY. It also has a first support structure 103, which is aligned in the first plane XY. The at least one first cable 102 is integrated into the first support structure 103, and the support structure 103 has a first region B1, in which the at least one first cable 102 runs, and a second region B2, in which no cable runs. The first region B1 of the support structure 103 can be separated from the second region B2 of the support structure 103 by mechanical separation.For the purpose of release, the illustrated cable arrangement has 100 perforations 108 along the first area B1 of the support structure 103, wherein during release the first area B1 of the support structure 103 is mechanically separated from the second area B2 of the support structure 103 by cutting through the perforations 108.

[0030] A preferred embodiment of a method for providing at least one first (ribbon) cable 2 by means of a (ribbon) cable arrangement 1 is described below. The method comprises at least the following steps: providing and aligning the at least one first ribbon cable 2 in a first plane XY and a first support structure 3 in the first plane XY or parallel to the first plane XY; providing an adhesive between the first support structure 3 and the at least one first ribbon cable 2; connecting the first support structure 3 and the at least one first ribbon cable 2 so that the at least one first ribbon cable 2 is fixed to the first support structure 3; and releasing the fixation by mechanically separating the at least one first ribbon cable 2 and the first support structure 3. All of these steps can preferably be automated.

[0031] The process steps up to the point of releasing the fixation can be repeated for at least one separate second support structure 5 and at least one separate second ribbon cable 4. In practice, the steps can be repeated any number of times until the desired number of ribbon cables (strands, for example, for a compound cable harness) are provided on a predetermined number of support structures. Afterwards, at least the first and separate second support structures 3, 5 can be arranged in a space-saving manner in a transport box 10. In the Fig. 2In the illustrated embodiment, the first, second, and third support structures 3, 5, 7 are laid flat on top of each other or stacked in the transport box 10. Preferably, the second (and third) support structure 5 (7) has the same dimensions as the first support structure 3, so that the first and second (and third) support structures 3, 5 (7) can be arranged in the transport box 10 in a space-saving manner. In particular, the first, second, and third support structures 3, 5, 7, which are aligned in or parallel to the first plane XY, can be stacked on top of each other in a third direction Z. Because all support structures 3, 5, 7 have the same dimensions, the individual ribbon cables 2, 4, 6 (on separate support structures 3, 5, 7) and their relationship to each other in the predetermined final state can be represented by the present ribbon cable arrangement 1, for example, when they are to form a composite ribbon cable harness.

[0032] In particular, the outer contour of the transport box 10 essentially corresponds to the dimensions of the first, second, and third support structures 3, 5, 7 in the first plane XY, so that positioning of the first, second, and third support structures 3, 5, 7 can be easily achieved by positioning the transport box 10. In particular, no elaborate packaging is necessary for the transport box 10. A packaging solution, as described in Fig. 2The rectangular transport box 10 shown is sufficient to allow the transport box 10 to be positioned as desired. In a preferred embodiment, the transport box 10 has a size of DIN A2 or DIN A1 for ease of handling. The transport box preferably has a flat base so that the precise picking positions can be detected, for example, via camera recognition. In an alternative embodiment, the support structures can be centered using centering pins in the transport box or packaging and centering holes in the support structure.

[0033] Before releasing the fixation, the method preferably includes the following steps: providing the transport box 10 at a production line and scanning and / or removing the at least one first ribbon cable 2 with the first support structure 3 fixed to it from the transport box 10. The delivery and provision of the transport box 10 at the production line can be automated. The transport box 10 can be automatically detected, aligned, and / or opened. An optical sensor, such as a camera, can scan the contents of the transport box 10. Preferably, the at least one first ribbon cable 2, or each ribbon cable 4, 6, has a plurality of optical markings that are recognizable in the first XY plane. A plurality of optical markings means at least one separate optical marking, with or in a reliably defined coordinate system.The optical markings can, for example, include laser-etched or printed optical markings. In a preferred embodiment, the optical sensor is directed from the third direction Z towards the first plane XY and can detect the optical markings, in particular all optical markings on the first, second and third ribbon cables 2, 4, 6, (at least layer by layer) and determine the type, position and orientation of the ribbon cable(s) 2, 4, 6 on the uppermost support structure 3 (see figure). Fig. 2 ) scan and / or recognize 10 items in transport box.

[0034] In a preferred embodiment and with reference to Fig. 2A gripping device removes at least the first flat ribbon cable 2 with the first support structure 3 from the transport box 10. The gripping device can include a suction or vacuum gripper to grasp the flat ribbon cable, which is lightweight and has a large surface area for gripping by means of negative pressure / vacuum. In particular, the first flat ribbon cable 2 is gripped to remove it from the transport box 10 with the known positioning and orientation and to maintain or change the positioning and orientation in a predetermined manner in order to make the first flat ribbon cable 2 available for further process steps.

[0035] To mechanically separate the first support structure 3 from the first ribbon cable 2, in a preferred embodiment, the first support structure 3 can be gripped by a separate second gripper and pulled off the first ribbon cable 2. The pulling action is similar to that of a peel-off film. The second gripper can be designed as a jaw gripper and clamp the first support structure 3 between its jaws. As an alternative method of mechanical separation, when releasing the fixation, in addition to pulling the first support structure 3 off the at least one first ribbon cable 2, or vice versa, a perforation in the first support structure 3 along the at least one first ribbon cable 2 can be cut.The perforation, preferably in the form of small holes or depressions, in the first support structure 3 can be subsequently created to fix the first ribbon cable 2 on the first support structure 3 and replicate the outer contours of the ribbon cable 2 on the first support structure 3.

[0036] Finally, at least one of the first ribbon cables 2 is positioned on the production line. The first ribbon cable 2, detached from the first support structure 3, can be installed in a vehicle or made available for further process steps on the production line. The position of each ribbon cable 2, 4, 6 on its respective support structure 3, 5, 7 ensures that the newly removed ribbon cable 2 is correctly positioned on the production line in relation to the other ribbon cables 4, 6 (which have already been removed from the transport box 10 or are yet to be removed). In particular, no additional preparation for positioning is necessary. Without the (first) support structure 3, the (first) ribbon cable 2 can be inserted into the production line or a vehicle body without any (unnecessary) interference from the (first) support structure 3.Afterwards, the subsequent flat ribbon cable 4, 6, which is provided on the first or a further support structure 3, 5, 7 in the transport box 10, can be scanned and / or removed, separated from the support structure 3, 5, 7 and positioned on the production line. REFERENCE MARK LIST

[0037] 1 (Flat ribbon) cable arrangement 2 First (Flat ribbon) cable 3 First support structure 4 Second (Flat ribbon) cable 5 Second support structure 6 Third (Flat ribbon) cable 7 Third support structure 10 Transport box 100 Cable arrangement 102 First cable 103 First support structure 108 Perforations B1 First area B2 Second area X First direction Y Second direction Z Third direction X-Y First level

Claims

1. Cable arrangement (1) for providing at least one first cable (2) comprising: a) at least one first cable (2) aligned lengthwise in a first plane (XY); and b) a first support structure (3) aligned in or parallel to the first plane (XY); wherein c) the at least one first cable (2) is fixed to the first support structure (3) by means of an adhesive; and d) the fixation can be released by mechanical separation of the at least one first cable (2) and the first support structure (3).

2. Cable arrangement (100) for providing at least one first cable (102) comprising: a) at least one first cable (102) aligned lengthwise in a first plane (XY); and b) a first support structure (103) aligned in the first plane (XY); wherein c) the at least one first cable (102) is integrated into the first support structure (103) and the support structure (103) has a first region (B1) in which the at least one first cable (102) runs and a second region (B2) in which no cable runs; and d) the first region (B1) of the support structure (103) can be detached from the second region (B2) of the support structure (103) by mechanical separation.

3. Cable arrangement according to claim 1 or 2, wherein the first support structure (3, 103) comprises a film-like element, in particular a plastic film.

4. Cable arrangement according to claim 1, wherein the adhesive comprises a releasable adhesive or temporarily molten plastic on the first support structure (3) and / or the at least one first cable (2), wherein the at least one first cable (2) is mechanically separated by peeling it off the first support structure (3), or vice versa.

5. Cable arrangement according to claim 1 or 2, wherein the first support structure (3) has perforations along the at least one first cable (2), wherein the at least one first cable (2) is mechanically separated from the first support structure (3) by cutting through the perforations, or vice versa; or wherein the first support structure (103) has perforations (108) along the first region (B1), wherein the first region (B1) of the support structure (103) is mechanically separated from the second region (B2) of the support structure (103) by cutting through the perforations (108).

6. Cable arrangement according to claim 1 or 2, wherein the at least one first cable (2) or the first area (B1) of the support structure (103) has a plurality of optical markings that are visible in the first plane (XY).

7. Cable arrangement according to claim 1, further comprising at least one separate second support structure (5) to which at least one separate second cable (4) is fixed, wherein the first and the second cable (2, 4) can form a composite cable harness without the respective first and second support structures (3, 5).

8. Cable arrangement according to claim 7, wherein the second support structure (5) has the same dimensions as the first support structure (3), so that the first and second support structures (3, 5) can be arranged in a space-saving manner in a transport box (10).

9. A method for providing at least one first cable (2) by means of a cable arrangement (1) according to claim 1, wherein the method comprises at least the following steps: a) providing and aligning the at least one first cable (2) in a first plane (XY) and a first support structure (3) in the first plane (XY) or parallel to the first plane (XY); b) providing an adhesive between the first support structure (3) and the at least one first cable (2); c) connecting the first support structure (3) and the at least one first cable (2) so that the at least one first cable (2) is fixed to the first support structure (3); and d) releasing the fixation by mechanically separating the at least one first cable (2) and the first support structure (3).

10. Method according to claim 9, further comprising, prior to releasing the fixation, the steps of: repeating the preceding steps for at least one separate second support structure (5) and at least one separate second cable (4); and space-saving arrangement of at least the first and separate second support structure (3, 5) in a transport box (10).

11. The method of claim 10, further comprising the steps of: providing the transport box (10) at a production line before releasing the fixation; and scanning and / or removing the at least one first cable (2) with the first support structure (3) fixed thereto; and upon releasing the fixation, peeling the first support structure (3) away from the at least one first cable (2), or vice versa, or cutting a perforation in the first support structure (3) along the at least one first cable (2); and positioning the at least one first cable (2) at the production line.

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