Device and method for producing cable harness

Abstract

To overcoming disadvantages of what is known, and in particular to create an improved device for producing a cable harness which can be operated efficiently.SOLUTION: A device (1) for producing a cable harness includes: a presentation plate (2) having a front side on which cables of the cable (4) harness can be arranged, and handling elements for handling the cables of the cable harness; 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) has a pneumatic system with which an air cushion can be generated between the handling element (5, 5', 5") and the presentation plate (2) designed as a perforated plate. The handling elements (5, 5', 5") each include a front handling part (7) and a rear moving part (8).SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a device and method for manufacturing a cable harness. [Background technology]

[0002] A cable harness, such as that used in an automobile or aircraft, consists of a number of cables, each generally provided with a plug housing at their prefabricated cable ends. A cable harness is an arrangement of multiple cables in which the cables are assembled into a structure having a complex, branching geometry, often resembling a tree.

[0003] Conventionally, these processing steps are carried out manually or with suitable power hand tools on a laying plate, where the entire cable harness is tensioned on the laying plate, and in particular the worker must remove the nodes of the cable harness from the branch brackets of the laying plate in order to work accurately on the area.

[0004] A manually operated laying plate is described, for example, in US Pat. No. 10,923,250. A cable holding element can be attached to the presentation plate using a suction cup. For handling, this handling element has an elongated handle, with which the operator grasps the handling element and places it accordingly in the desired position. The cable holding element can be inserted via an arm that is provided with a hole and connected to a base with a suction cup. Furthermore, presentation plates are known that have a slot defined by a blind hole, into which the cable holding element can be directly inserted. This document contains a note stating that instead of the suction cup, the handling element can also be magnetically attached to the presentation plate.

[0005] EP 2 672 490 A1 discloses a device of a comparable type with a horizontal presentation plate to which a handling element is magnetically attached, which has a U-shaped guide in which a cable can be positioned. The U-shaped guide is rectangular in plan view and is connected to a base which is provided with a magnet. Furthermore, a flat friction element is arranged on the base to prevent slippage. The handling element is difficult to handle and cannot be easily repositioned to another position on the presentation plate. Another problem is that it is only suitable for manual operation. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] U.S. Patent No. 10923250 [Patent Document 2] European Patent Application Publication No. 2672490 Summary of the Invention [Problem to be solved by the invention]

[0007] SUMMARY OF THE DISCLOSURE The object of the present invention is therefore to overcome the drawbacks of the known, in particular to create an improved device for manufacturing cable harnesses that can be operated efficiently. [Means for solving the problem]

[0008] According to the invention, this object is achieved by a device having the features of claim 1. The device for producing a cable harness comprises a presentation plate, on which the cables of the cable harness of the presentation plate can be placed, and a handling element for handling the cables of the cable harness. When producing a cable harness, positions and areas of the cable harness may need to be fixed. For example, in doing so, branches and nodes can be fixed using suitable tools (for example, spot tape or cable ties). It may also be necessary to provide additional protection in the entire cable harness or in areas (for example, by taping it with an adhesive tape). Furthermore, it may be necessary to provide the cable harness with attachment elements, such as clips, at predetermined positions, to allow the cable harness to be finally installed in its intended device, such as a motor vehicle. The above-mentioned processing of the cable harness is also known to those skilled in the art as "molding" or "installation", since a tree-like structure is created from a plurality of individual cables.

[0009] The purpose of the presentation plate is, among other things, to present the cables or cable harnesses of a cable harness on this plate so that the cables or cable harnesses can be fixed or taped manually or mechanically in a specified position by a fixing device such as a spot tape. Handling element is understood in the following to mean an element with which a single cable or multiple cables are handled so that they can be processed to produce a cable harness. One such processing is, for example, the fixing of certain points and areas of a cable harness using suitable tools (e.g. spot tape, cable ties). Here, the presentation plate can be aligned vertically. Instead of a vertical presentation plate, other orientations such as a horizontal presentation plate or an inclined presentation plate are also conceivable.

[0010] The handling element is magnetically attached or attachable to the presentation plate and is preferably designed so that it can be moved in all directions in the plane defined by the presentation plate. Magnetic attachment has the advantage that it can be reliably fixed in a given position on the presentation plate and at the same time the position of the handling element can be changed quickly and without great effort. The device has a pneumatic system which can create an air cushion between the handling element and the presentation plate so that the handling element can be moved efficiently on the presentation plate.

[0011] To create an air cushion between the handling elements and the presentation plate, the presentation plate can be designed to be air-fillable. The presentation plate can be actively or passively air-filled. In the case of an actively air-fillable presentation plate, the presentation plate can have, for example, evenly distributed and preferably individually controllable air nozzles on its upper side, which blow out air so that an air cushion is created in the area of ​​the handling elements. In this case, a pneumatic system is assigned to the presentation plate. However, a pneumatic system may also be assigned to the handling elements (passive filling of the presentation plate).

[0012] If necessary, in particular for moving handling elements magnetically attached to the presentation plate, the pneumatic system can be activated by suitable control, so that an advantageous air cushion is formed by the pneumatic system between the handling elements and the presentation plate.

[0013] In certain applications it can be advantageous if the pneumatic system is designed to increase the adhesion of the handling elements to the presentation plate by means of a vacuum if necessary. In this way variability and applicability can be increased even more significantly.

[0014] For the pneumatic filling of the presentation plate, the presentation plate can be designed as a perforated plate, which preferably has a number of holes distributed in the presentation plate, through which compressed air can be passed to form an air cushion between the handling element and the presentation plate. The holes are therefore preferably designed as through holes, by which the compressed air can pass from the front of the presentation plate to the rear of the presentation plate (and vice versa is of course also possible). In this way, after the pneumatic system is activated, two air cushions can be formed on the presentation plate, i.e. one air cushion in the area of ​​the front area and one air cushion on the opposite side (rear).

[0015] The handling elements can each comprise a front handling part and a rear movable part, the handling part and the associated movable part being attached to the intermediate presentation plate by magnets, preferably by permanent magnets, so that when the movable part is moved, the handling part can be moved together with the movable part. During this movement of the handling element on the presentation plate, the air cushion causes friction between the movable part and the presentation plate on the one hand and reduces friction between the handling part and the presentation plate on the other hand, thus making the movement easier and can be carried out especially without great effort. Obviously, the device is designed in such a way that two air cushions, or one air cushion with two partial cushion segments per handling element, can be created in the pneumatic system itself.

[0016] The division of the handling element into a front handling part and a rear movable part has great advantages. Such a two-part handling element with a front handling part and a rear movable part can be easily and reliably attached to the presentation plate and can be moved exactly to the desired position on the presentation plate. The handling part at the front with respect to the presentation plate, facing the cable harness, is used for the actual handling of the individual parts of the cable harness and comprises means by which cables, for example in the form of cable bundles, connector housings, prefabricated cable ends with branches etc., can be gripped, held together or otherwise handled. The movable part at the rear with respect to the presentation plate is used for moving the handling element. In other words, the handling element can be moved manually or mechanically via the movable part. While moving the movable part on the presentation plate, the handling parts are moved in unison. The division ensures an efficient and trouble-free operation, since the moving elements required for handling and moving do not get in each other's way. Automation of the device is also easily possible thanks to the division. However, intermediate forms are also conceivable in which the movement is performed automatically and at least certain operations on the cable harness in the front part are performed manually.

[0017] For magnetic attachment, the presentation plate designed as a multi-hole plate can particularly preferably be made of a non-ferromagnetic material. If the handling elements each comprise a front handling part and a rear movable 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, the other parts either containing a ferromagnetic material or also equipped with permanent magnets such that the permanent magnets attract each other.

[0018] Permanent magnets can be used to magnetically attach the handling elements to a preferably vertical presentation plate, with the help of which the handling elements can be held reliably in the desired position on the presentation plate. Preferably, permanent magnets (e.g. neodymium magnets) are selected that are strong enough to prevent the handling elements from accidentally coming loose from the presentation plate, even with higher loads. However, it can also be advantageous if only permanent magnets strong enough are selected so that the handling elements can be easily replaced by hand if necessary. The changing process can also be supported by a pneumatic system.

[0019] Permanent magnets have the advantage that they ensure reliable operation in a simple manner and remain in their current position on the presentation plate, especially in the event of a fault (e.g. in the event of an unexpected power outage due to a utility power outage).

[0020] In a preferred embodiment, the above-mentioned vertical presentation plate, on which the cables of the cable harness can be placed in front of the presentation plate, can be made of a non-ferromagnetic material. The or each handling element can each comprise a front handling part and a rear movable part, at least one of the parts of the respective handling element (i.e. the handling part, the movable part) comprises a permanent magnet for magnetic attachment to the presentation plate, the other part comprises a ferromagnetic material or the other part also comprises a permanent magnet, but with different poles, so that the permanent magnets attract each other (hence the handling part and the movable part roughly correspond to one permanent magnet and one ferromagnetic material, or two permanent magnets with different poles so that the permanent magnets attract each other). The latter case with two permanent magnets should be understood to mean that the permanent magnets are arranged and oriented with respect to each other such that the different poles face each other so that the permanent magnets attract each other.

[0021] Each handling element may have at least one chamber open towards the presentation plate, and if there are handling parts and mobile parts as described above, preferably the front handling part on the one hand and the rear mobile part on the other hand each have a chamber open towards the presentation plate. Thanks to the chambers, a stable and reliable air cushion can be created so that the handling parts can be advantageously moved on the presentation plate. A support edge can define the respective chamber on the outer side. This support edge can extend in the direction of the plate and thus in the case of a vertical plate in the horizontal direction. The support edge can preferably be circular.

[0022] The movable part can have a coupling part connected to the slide part. The slide part is understood to mean the part facing the presentation plate, which is in contact with the presentation plate and slides along it when moved. Thanks to the air cushion, the slide is almost frictionless. The permanent magnet is preferably integrated into the slide part. However, the slide part can also consist of or contain a ferromagnetic material. The slide part can be assigned to the above-mentioned support edge, which can contact, support or be supported on the surface of the presentation plate. The coupling part, on the other hand, is the part facing away from the presentation plate.

[0023] The handling part can have a handling head connected to the slide part. Preferably, the two slide parts of the one mobile part and the other handling part are designed identically. The slide part of the handling part can be designed substantially identical to the body of the mobile part, in particular with regard to its dimensions and in particular with regard to its base area. The permanent magnet is preferably integrated into the slide part. However, the slide part can also consist of or contain a ferromagnetic material. The above-mentioned support edge can be assigned to the slide part.

[0024] The slide itself can be constructed in two parts. A two-part slide can have a front slide piece for the presentation plate and a main body (as the rear part). The slide piece and the main body can be made of different materials. For example, the slide piece can be made of plastic and the main body can be a metal part.

[0025] To seal the chamber from the outside, the support edge can be designed as a flexible rubber seal. It can be advantageous if an elastomeric sealing lip is provided or arranged on the support edge.

[0026] Each handling element, in particular the moving part of the handling element, can have a pneumatic connection by which compressed air can be supplied to the handling element or by which a vacuum can be created if required.

[0027] The device may have a positioning system for moving the handling elements to the desired position, this positioning system being preferably integrated in the presentation plate, the integrated positioning system being in particular formed by a gantry robot, the positioning system for moving the handling elements comprising a positioning head with a coupling for a mechanical coupling by which the positioning system can in each case bring about a mechanically operable connection with the handling element, the pneumatic coupling being preferably integrated in the coupling by a pneumatic connection designed as a complementary lance to the pneumatic connection of the handling element. Using the gantry robot the handling elements can be moved quickly and precisely to the desired position and, depending on the requirements, even complex paths 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.

[0028] In order to move a number of handling elements, the positioning system may comprise a positioning head with a number of couplings with which the positioning system may provide a mechanically operable connection (i.e. coupled) with one or more handling elements, such that the movement of the positioning head may then be transmitted to the handling elements. The couplings may be movable separately or together with one another, at least relative to the plane of the presentation plate. These multiple couplings may be rigidly connected to one another. However, it may be advantageous if the multiple couplings can be moved separately relative to one another, at least relative to the plane of the presentation plate, allowing even more complex movements.

[0029] In a preferred embodiment, the movable part of the handling element can be a coupling part with a spherical outer contour for the mechanical coupling, the outer contour having a spherical flattening. In this case, for example, an insertion opening sealed or sealable by an O-ring, into which a lance is inserted or can be inserted, can be arranged in the coupling part for the pneumatic connection to create the pneumatic connection.

[0030] A further embodiment relates to a device in which at least some of the handling elements are designed as housing holders for holding housings. Each housing holder can temporarily hold a single or possibly even several housings for the production of a cable harness. Housings, which are intended in particular to make an electrical plug-in connection, or more precisely pre-manufactured cable ends provided with housings, can be moved to the desired position on the presentation plate thanks to the housing holder. The housing holder can comprise a housing receptacle into which the housing(s) can be inserted in order to hold the housing securely, or other means for temporarily holding the housing. The housing holder is assigned to a housing holder handling head.

[0031] Alternatively or additionally, at least some of the handling elements can be designed as deflectors for deflecting the path of the cables. If the housing holder is seen as a first type of handling element, then the deflectors for deflecting the path of the cables of the cable harness (one or optionally several cables can be deflected, in the case of several cables the cables are usually present as loose or already fixed cable bundles) form the second type of handling element. For example, deflectors are usually used in the branching structure of the cable harness to bend individual cables at a predetermined position, for example at the branching.

[0032] Alternatively or additionally, at least some of the handling elements can be designed as hold-up means. The hold-up means form a third type of handling element. The hold-up means are used to lift the individual cable or cables combined in the form of a cable harness and thus increase the distance to the presentation plate in order to allow the cable to pass under the lifted individual cable or cables. For example, by one, preferably two hold-up means, the main strand of the cable harness can be held in a part further away from the positioning plate, whereby an enlarged gap is created under the thus lifted cable harness, whereby the other parts of the cable harness can be guided below unhindered, for example by a housing holder, thereby allowing further branching on two sides.

[0033] A further aspect of the invention relates to a device for manufacturing cable harnesses, in particular the device mentioned above, characterized in that the handling part attached or attachable to the presentation plate has a handling head adjacent to the slide part, the handling head being preferably rotatably connected to the slide part with respect to a normal direction predetermined by the presentation plate, and the bearing for the rotatable connection between the handling head and the slide part has a locking mechanism for fixing the handling head in a desired rotational position (fixed position). The normal direction is understood here to be the direction extending perpendicularly to the plane of the presentation plate. The axis of rotation of the handling head rotatably connected to the slide part in the normal direction can therefore be a horizontal axis of rotation in the case of a vertical presentation plate.

[0034] Preferably, the locking mechanism is operatively connected to the pneumatic system to create an air cushion between the handling element and the presentation plate such that, after appropriate control of the pneumatic system, the rotation lock can be released by the locking mechanism and the handling head is freely rotatably connected to the slide.

[0035] The device can then comprise a handling robot, with the aid of which fixing means can be attached to the cable for installation and fixing the cable point by point or section by section. This handling robot, designed for example as an articulated arm robot, can be placed in the area behind the presentation plate, which is usually separate, in contrast to the preferred positioning system. The handling robot can be firmly connected to the ground or designed to move autonomously above the ground.

[0036] With regard to this method, the invention is characterized in that (i) the cables, provided with housings and required for the cable harness, are placed on a presentation plate using housing holders and other handling elements, which are magnetically attached to the presentation plate, and (ii) the handling elements are moved on the presentation plate by introducing compressed air into one or more handling elements, which are moved by a pneumatic system, thereby creating an air cushion between the handling elements and the presentation plate. This method for manufacturing a cable harness can be carried out in particular using the device described above.

[0037] If the handling elements each comprise a front handling part and a rear movable part, the respective handling elements can be magnetically attached to the presentation plate, in that the handling part and the movable part attract each other and thus adhere together to the presentation plate. In the case of magnetic attachment, the intermediate presentation plate is clamped to some extent between the handling part and the associated movable part by or under the influence of magnetic forces. In other words, the presentation plate in between is clamped by the attractive force of the magnets assigned to the handling part on the one hand and to the movable part on the other hand.

[0038] At least one of the parts of each handling element may be provided with a permanent magnet for magnetic attachment to the presentation plate, while other parts include ferromagnetic material or are also provided with permanent magnets such that the permanent magnets attract each other.

[0039] The handling elements can be moved in individual steps. It can be advantageous if, after completion of a single-step movement of the handling elements, the compressed air supply is first disconnected from the handling elements and then, i.e. after decoupling, the mechanical coupling of the handling elements to the positioning system is released in order to move the handling elements to the desired position. The two steps of decoupling the compressed air supply and releasing the mechanical coupling can be performed very quickly one after the other.

[0040] If the handling element has to be held on the presentation plate with higher adhesive forces, a vacuum can be created between the handling element and the presentation plate, thus temporarily fixing the handling element reliably and substantially immovably on the presentation plate.

[0041] Further particular features and advantages of the invention can be derived from the following description and drawings of exemplary embodiments. [Brief description of the drawings]

[0042] [Figure 1] FIG. 2 shows a perspective view of a device according to the invention for producing cable harnesses, having a presentation plate and a number of handling elements mounted thereon (presentation plate seen from the front). [Diagram 2] 2 shows the device of FIG. 1 in perspective views from different viewing directions (presentation plate seen from behind). [Diagram 3] FIG. 2 shows an enlarged perspective view of a presentation plate and three types of handling elements (housing holder, deflector, hold-up means) for the device according to FIG. 1. [Figure 4] FIG. 2 shows a perspective view of a positioning head with several couplings for moving the handling elements and the handling elements designed as a housing holder. [Figure 5a] FIG. 2 shows a plan view of a presentation plate on which the movable part of the handling element is placed. [Figure 5b] 1 shows a presentation plate of an alternative design. [Figure 6] 1 is a side view with a cutaway of a handling element of a device according to the invention designed as a housing holder and mounted on a presentation plate; [Figure 7] FIG. 7 shows the handling element of FIG. 6 with the joints of the positioning system connected at a slight angle. [Figure 8] 4 shows the handling element with the just coupled coupling of the positioning system in a position in which the rotational lock of the handling head to the slide caused by the locking mechanism is released. [Figure 9] FIG. 2 shows an enlarged perspective view of a presentation plate and handling elements designed as a housing holder with a handling head rotatably connected to the slide. [Figure 10]1 shows a plan view of components of an alternative presentation plate for a device according to the invention for manufacturing a cable harness; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0043] FIG. 1 shows a device 1 for manufacturing cable harnesses. Cable harnesses, such as those used, for example, in automobiles or aircraft, consist of several cables, each generally equipped with a plug housing at their prefabricated cable ends. Cable harnesses are these arrangements in which several cables or lines are assembled into structures with a complex and branched geometry, often resembling a tree. Each cable is usually an electric cable, comprising, for example, a solid conductor made of copper or aluminum or stranded wires and an insulation as sheath for the conductor. The term "cable" is to be understood broadly in the following. In this context, a cable is also understood to mean a cable unit consisting of several cables or lines of equal length combined into a unit, such as, for example, a twisted cable harness.

[0044] In addition to the device 1 shown in Fig. 1, the system may further comprise a cable treatment machine and a housing assembly machine (not shown here) which may be arranged upstream of the device 1. The cable treatment machine may 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, if necessary, one or more grommet stations. In the housing assembly machine, the connector housing is assembled with the previously prefabricated cable ends of the cables from the cable treatment machine.

[0045] After wiring, the cable harness needs to be prepared for the intended use so that it can be installed in the intended device, such as a vehicle. The cables required for the respective cable harness, e.g. assembled with the cable processing and housing assembly machines described above, are assembled into a tree-like structure by the device 1, which will be described in detail below. The branches and nodes must then be fixed using suitable fixing means (e.g. spot tape or cable ties). The cable harness may need to be provided with additional protection, either completely or in areas (e.g. by taping with a resistive adhesive tape).

[0046] The device 1 for producing cable harnesses comprises a vertical presentation plate 2 on which the cables of the cable harness can be placed in front of the presentation plate 2. The cables, already assembled and with their housings, indicated with 4, are arranged in the intermediate position shown in Fig. 1, in the form of loops that hang more or less freely on the presentation plate 2. The housings of the cables 4 are held in housing holders 5. In Fig. 1 two further types of handling elements can be seen, namely deflectors marked with 5' and hold-up means marked with 5''. These handling elements are arranged in a waiting position in a parking zone at the edge of the presentation plate 2. These handling elements wait until they are used to produce a cable harness as required.

[0047] The device 1 further comprises in the rear area of ​​the presentation plate 2 a handling robot 40, with the aid of which fixing means can be attached to the cable 4 in order to fix the cable 4 point by point or section by section. The handling robot 40 can, for example, apply spot tape. The handling robot 40 is designed in this case as an articulated arm robot, which can be rigidly connected to the floor or designed to move autonomously above the floor.

[0048] As can be seen from the rear view of the presentation plate 2 according to FIG. 2, the handling elements 5, 5', 5'' can be moved in all directions in the plane defined by the presentation plate 2 by a gantry robot above the presentation plate.

[0049] The presentation plate 2 is preferably made of a non-ferromagnetic material. It can be made of stainless steel, for example. However, other metal plates made of non-ferromagnetic materials can also be used for the presentation plate. The presentation plate 2 can also be made of plastic.

[0050] Each of the handling elements 5, 5', 5'' comprises a front handling part 7 and a rear mobile part (8, see FIG. 2), the handling part 7 and the mobile part each being equipped with a permanent magnet for magnetic attachment to the presentation plate such that the permanent magnets attract each other. For this purpose, the permanent magnets are arranged and oriented relative to each other such that different poles face each other, whereby the permanent magnets attract each other. When the mobile part is moved over the presentation plate, the handling part is entrained. One permanent magnet can be provided for each part (handling part, mobile part). However, it is also possible, advantageously for each part, to provide several permanent magnets.

[0051] The attractive force of the magnets causes a clamping of the intermediate presentation plate 2. The handling elements 5, 5', 5'' therefore remain in their position on the vertically aligned presentation plate 2.

[0052] In order to temporarily reduce the static friction of the handling elements 5, 5', 5'' on either side 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 that can create an air cushion between the handling elements 5, 5', 5'' and the presentation plate 2. The two parts of the handling elements 5, 5', 5'' (the joining part and the handling part) have one chamber each for building up the air cushion.

[0053] Thanks to the air cushion, the strong adhesive forces arising from the permanent magnets can be reduced, whereby the handling elements 5, 5', 5'' can be moved easily and effortlessly on the presentation plate 2. In the figure, a compressor 20 of the pneumatic system is shown as a source of compressed air for operating the pneumatic system. The compressed air source in this case is integrated into the device 1. The compressed air source, e.g. a compressor or a separate compressed air source for supplying compressed air, can of course also be arranged externally. Furthermore, a compressed air supply line is conceivable for supplying compressed air.

[0054] Especially for larger cable harnesses, the clamping force of the magnets must be large enough to enable the handling elements 5, 5', 5'' to retain their position despite the additional weight on the presentation plate 2, so the magnets are designed accordingly strong.

[0055] Thanks to the pneumatic system, relatively simple positioning systems can be used that do not need to be designed to be particularly strong or robust, as the air cushion means that the high static friction caused by clamping with magnets no longer has to be overcome.

[0056] Figure 2 shows the device 1 with a rear view of the presentation plate 20, where the movable parts are visible and marked with 8. In this case the movable parts 8 of all types of handling elements 5, 5', 5'' are designed substantially identically.

[0057] The mobile part 8 is responsible for the movement of the handling elements 5, 5', 5''. In order to move the handling elements to the desired positions, the device 1 has a positioning system 3. The positioning system 3, integrated in the presentation plate 2, is in this case formed by a gantry robot. The positioning system 3 or gantry robot has a beam-shaped gantry carriage which can be moved back and forth in the x-direction along a linear guide and a second carriage which can be moved back and forth along the gantry carriage in the y-direction orthogonal to the x-direction and which is equipped with a positioning head 31. The positioning head 31 of the gantry robot forms, so to speak, an interface to the handling elements. The positioning head 31 can grip the handling element via coupling means and bring the handling element to the desired position by a controlled movement of the gantry robot. For this purpose, the positioning head 31 has at least one coupling which can engage with a coupling of the handling element for the movement.

[0058] FIG. 3 shows three different types of handling elements, namely the housing holder 5, the deflector 5′ and the hold-up means 5″. The handling elements differ substantially in the different design of the front handling part, while the rear movable part is of approximately the same design for all handling elements. The handling part 7 of the housing holder 5 has a handling head 19 which is rotatably connected to a slide part 18. The housing holder 5 has a means for temporarily holding the housing, for example in this case a housing receptacle, into which the housing can be inserted for secure holding. The handling parts of the deflector 5′ and the hold-up means 5″ have slide parts which are designed similarly to the slide part 18 of the housing holder 5, at least in terms of external shape and dimensions. The differences consist mainly in the different design of the respective handling heads. The handling part of the deflector 5′ has a handling head which obviously has a hook. The handling part of the hold-up means 5 ″ comprises a handling head with a U-shaped cable receiver in which the cables are bundled and held loosely together, the cable receiver for lifting being further away from the presentation plate 2 .

[0059] The handling part of the deflector 5' can have a handling head connected to the slide part, which is fixedly or preferably freely rotatably connected to the slide part. When the deflector is attached to the presentation plate 2, the axis of rotation extends relative to the normal direction (z-direction) defined by the presentation plate 2. The handling head of the deflector 5' is designed to remain in a vertically aligned basic position by gravity when the deflector 5' is attached to the presentation plate 2. The same applies to the hold-up means 5''. The hold-up means 5'' also has a handling head 19'' connected to the slide part and which is freely rotatably connected to the slide part 18. The handling head 19'' of the hold-up means 5'' is designed to remain in a vertically aligned basic position by gravity when the hold-up means 5'' is attached to the presentation plate 2.

[0060] The handling elements 5, 5', 5'' are attached to a presentation plate 2 designed as a perforated plate and made of a non-ferromagnetic material, which has a number of through holes 6 evenly distributed in the presentation plate, through which compressed air can be passed to create an air cushion between the handling elements 5, 5', 5'' and the presentation plate 2.

[0061] The operation of the pneumatic system of the device 1 is explained below on the basis of figures 4 to 8. Figure 4 relates to a perspective view of a positioning head 31 with several couplings for moving the handling elements and of a handling element 5 designed as a housing holder, the handling element 5 being positioned so that its couplings 17 are more clearly visible for a better understanding of the interface.

[0062] The positioning head 31, which is assigned to the gantry robot of the positioning system 3, has several couplings 32. In this case, the positioning head 31 has, for example, four couplings 32. By means of the couplings 32, four handling elements can be moved simultaneously. In FIG. 4, the front coupling 32, seen from the observer's point of view, is in an extended position in which coupling is possible. The remaining three couplings are in a rest position. In this position, only one handling element can be moved together with the positioning system 3. However, if necessary, additional or other couplings can be extended to create a working position, so that more than one handling element can be moved. Of course, it is conceivable that the positioning head 31 of the positioning system 3 is equipped with only one such coupling 32.

[0063] Each coupling 32 is designed like a socket for a mechanical coupling. A pneumatic coupling, designed as a lance 33, is integrated into the coupling. The lance 33 is clearly located in the center of the cavity of the coupling 32.

[0064] The coupling 32 is mounted so as to be movable to a limited extent relative to the positioning head 31 in a normal direction defined by the presentation plate 2. 35 denotes a compressed air supply line of a pneumatic system, supplying compressed air to the lance 33. 34 denotes a pneumatic actuator, with the aid of which the coupling 32 can be extended from a rest position to an actuated position. The coupling can be preloaded in the rest position, for example by a spring (not shown).

[0065] Each of the couplings 32, which can be extended by a pneumatic actuator 34, has a plate-like segment 36 in which a sealed transverse bore (not shown) is disposed for directing compressed air from a compressed air supply line 35 to the lance 33. The compressed air supply line 35 is a rigid tube with a seal to allow it to follow the movement during extension and retraction. The actuator 34 comprises a piston rod extending coaxially with the lance.

[0066] The handling element 5, as can be seen from Fig. 4, consists of a front handling part 7 and a rear movable part 8. The presentation plate 2 is not shown in Fig. 4. However, "a" indicates the distance or spacing between the handling part 7 and the rear movable part 8, which distance corresponds to the thickness of the presentation plate 2. The presentation plate, which is not shown here, is contacted by the slides 14, 18 of the handling part 7. The slide 14 is part of the connecting part 17 of the handling element 5 and is therefore assigned to the movable part 8. The slide 18 is assigned to the handling part 7.

[0067] The coupling 17 of the handling element 5 has a spherical outer contour for the mechanical coupling and has a spherical flattening 22. The spherical shape is intended to make it possible to compensate for slight angular errors between the presentation plate and the positioning system. The flattening serves to prevent the handling element from rotating when moving over the presentation plate.

[0068] If a particular handling element is to be moved, the positioning head 31 is moved towards the handling element by the gantry robot and then the coupling 32 is extended. When the coupling 32 is extended, it comes into contact with the coupling 17 assigned to the handling element. The coupling process is now completed and the handling element can now be moved. However, before the start of the movement, the pneumatic system is activated and compressed air is supplied to the handling element. An air cushion is formed between the handling element and the presentation plate. The handling element can then be moved virtually frictionlessly on the presentation plate.

[0069] Figure 5a shows the hole pattern of the presentation plate 2. The holes 6 form a kind of perforated sieve structure and are equally spaced in a rectilinear grid distributed on the presentation plate 2. In figure 5a, 11 further indicates the support edge of the slide piece of the handling element 5. This slide piece can be assigned either to the handling part or to the movable part, since the respective slide pieces of both elements (handling element, movable part) are substantially identical in design.

[0070] Figure 5b shows a variation of the hole pattern of the presentation plate 2, in which the holes 6 are arranged in alternating rows and offset to form triangles, as shown by the dashed lines.

[0071] The hole pattern can be square (figure 5a) or triangular (figure 5b). In this regard, in a preferred embodiment, the holes 6 must always be located within the air chamber area of ​​the handling element, in other words at least an additional area of ​​the holes 6 must always be within the chamber area to ensure a continuous moving surface during movement of the handling element on the presentation plate.

[0072] Furthermore, the size of the hole, which in this case is for example circular, is advantageously selected such that its diameter d is smaller than the thickness D of the supporting edge 11 of the handling element.

[0073] More details on the design of the structure of the handling element 5 can be taken from figures 6 and 7. Here, a housing holder is shown. The structure of the other handling elements, such as the deflectors and the hold-down devices, is basically the same, except for the handling head. Figure 6 shows a handling element 5, which is magnetically attached to the presentation plate 2 and designed, for example, as a housing holder. In the handling part 7 on the one hand and in the mobile part 8 of the handling element 5 on the other hand, one or more permanent magnets, here indicated with 9 and 10, are inserted. The relevant parts each have corresponding receptacles in the slide parts 14, 18 into which the permanent magnets 9, 10 are inserted. The slide parts are constructed identically and differ substantially only in the polarity of the magnets used. The slide parts 14, 18 themselves are constructed in two parts and consist of a front slide piece 15 relative to the presentation plate 2 and a body 16 as the rear part. The slide piece 15 is preferably made of plastic, the body 16 of metal. The handling part 7 of the handling element 5 has a chamber 13 that is open towards the presentation plate 2. The movable part 8 on the other hand has a chamber 12 which is open towards the presentation plate 2. The support edge 11 can define respective chambers 12, 13 on its lateral outer side.

[0074] The movable part 8 has a pneumatic connection by which compressed air can be supplied to the handling element 5. For this purpose, an insertion opening 23 is arranged in the coupling part 17, which can be sealed by an O-ring 24 and into which a lance (not shown here) can be inserted.

[0075] In FIG. 7, in which the cutaway view is slightly modified compared to FIG. 6, it is shown that after coupling, due to the inherently undesirable inaccurate positioning of the positioning head, the coupling 32 assigned to the positioning system 3 can still be connected to the coupling 17 even in a slightly tilted position. The mechanical coupling of the handling element 5 is designed spherically with flattening 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, a sufficient clearance is provided before and after the O-ring 24 so that here too the angular errors between the presentation plate and the positioning system can be compensated. It is therefore preferable that the compressed air coupling and the mechanical coupling are matched to each other so that the center of the sphere and the sealing O-ring 24 are at the same height.

[0076] The handling element 5 is therefore equipped with a compressed air connection so as to be able to take in compressed air and direct it into the first chamber 12 , through the presentation plate 2 and into the second chamber 13 .

[0077] A further advantage of the device 1 is that, if required, a vacuum can be created between the handling element 5 and the presentation plate 2 when the handling element 5 is adhesively held on the presentation plate 2. The pneumatic system can therefore operate the handling element 5 in two different states, i.e. one in which the compressed air creates an air cushion for movement and one in which the vacuum holds the handling element to the presentation plate with a particularly high holding force.

[0078] Thanks to this embodiment, a vacuum can also be temporarily created in the chamber via the positioning system 3. The vacuum increases the absorbable forces of the handling elements 5 and thus reduces the sensitivity of the handling of the cable branches of the cable harness. The vacuum can be provided via a compressed air supply line or can be created using a Venturi nozzle.

[0079] The handling element 5 can be moved in individual steps. After the displacement step, the positioning system first disconnects the compressed air supply and then the mechanical connection to the handling element. Otherwise undesirable sagging of the handling element 5 mounted on the vertical presentation plate 2 could occur. The two steps of disconnecting the compressed air supply and releasing the mechanical coupling can be performed very quickly, one after the other.

[0080] As mentioned above, compressed air can be supplied to the lance 33 from the compressed air supply line 35 via a lateral bore in the plate-like segment 36. However, other designs are also conceivable, such as designs without a separate line 35. For example, the compressed air for extending the coupling 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 an air cushion is built up. Once the target position is reached, the compressed air can be switched so that no new air is supplied via the piston rod, which causes the air cushion to deflate. To do this, the piston rod is pushed back with the redirected air. The coupling and the lance allow a certain stroke without losing contact, so that the handling part is still guided only for a short time of the backward movement.

[0081] According to a further embodiment, elastomeric sealing lips (not shown) can be installed around the chamber to make the air cushion or vacuum, if necessary, more efficient. These sealing lips can be formed on the slide piece 15 in the area of ​​the support edge 11 or attached to the slide piece.

[0082] Figure 8, in which the cutaway view is again modified in comparison with figures 6 and 7, shows a variant of the handling element 5 in which the bearing between the slide 18 and the handling head 19 has a special rotation lock. Here, in comparison with figure 7, the coupling 32 assigned to the positioning system 3 is connected to the coupling 17 of the handling element 5 in the normal coupling position which normally occurs.

[0083] When presenting a branching of a cable harness, a situation may arise where the cable branching and the handling head 19 of the handling element 5 are only aligned with each other (e.g. horizontal alignment) under large pulling forces. If further pulling forces are applied during processing of the branching (e.g. taping), the handling element 5 must be designed large enough to be able to absorb all forces. Therefore, in the embodiment shown in Fig. 8, the handling element 5, which is designed in particular as a housing holder, is complemented with a locking mechanism that can be separated by supplied compressed air.

[0084] The handling element 5, designed as a housing holder and mounted on the presentation plate 2, has a handling head 19 connected to the slide part 18, which is rotatably connected to the slide part 18 relative to the normal direction and a bearing for the rotatable connection between the handling head 19 and the slide part 18, which has a locking mechanism 25 for fixing the handling head in a desired rotational position (fixed position). The locking mechanism is operatively connected to a pneumatic system, so that by the pneumatic system, after appropriate control, the rotation lock created by the locking mechanism 25 can be released and the handling head 19 is freely rotatably connected to the slide part 18.

[0085] The locking mechanism 25 serves to determine the orientation of the handling head 19. By means of the supplied compressed air, the locking mechanism 25 is levered so that the handling head 19 can rotate freely according to the pulling force of the cable branch. The locking mechanism 25 can have a pitch of, for example, 45° or more (90°, 120° or 180°).

[0086] The locking mechanism 25 comprises a locking crown 26 arranged at the end of the piston 27, into which a locking cam 29 assigned to the handling head 19 engages or can engage in a locking manner. Furthermore, a piston rod 28, for example with a square cross section, can be seen. To release the rotation lock due to the locking connection, compressed air is fed into the piston chamber after suitable control, displacing the spring-loaded piston 27 in the e direction, whereby the locking crown 26 is disengaged from the locking cam 29 to such an extent that the locking connection is released and accordingly free rotation of the handling head 19 occurs. Figure 8 shows the locking mechanism in such a position that the locking mechanism is disengaged.

[0087] Thanks to this locking mechanism 25, the handling head 19 can be pulled in and held in a desired angular position, while the tensions in the branching of the cable harness are reduced, which has the further advantage that the handling elements 5 can be made smaller.

[0088] The separation of the locking mechanism 25 can be performed together with the construction of the air cushions with a common operating pressure or independently (by two operating pressures).

[0089] 9 shows a handling element 5 designed as a cable holder housing holder, with a handling head 19 rotatably connected to a slide 18. From the illustrated vertically aligned basic position, the handling head 19 can be rotated by 45° about an axis of rotation indicated with S. By means of a locking mechanism 25, the handling head 19 can be pulled into a desired angular position and held in the angular position indicated by the dashed line.

[0090] The presentation plate 2, shown in FIG. 3 and designed as a simple perforated plate, is passively air-filled. The pneumatic system is assigned to the handling element 5. However, actively air-filled presentation plate designs are also conceivable. Such an actively air-filled presentation plate, or its main components, is shown in FIG. 10. 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 each other, for example by gluing them together. The intermediate plate 38 has a channel-like recess 41 extending from edge to end which leads to the holes 6 after assembly. In this way, the individual holes 6 can be supplied from the edge with compressed air, controlled for example via a valve (not shown). An alternative actively pneumatically loaded presentation plate can, for example, have evenly distributed and preferably individually controllable air nozzles on its upper side, which blow out air so that an air cushion is created in the area of ​​the handling elements. [Explanation of symbols]

[0091] 2, 20 Presentation Plate 3.30 Positioning system 5 Housing Holder 5' Deflector 5'' Hold Up Means 5, 5', 5'' Handling elements 7 Handling section 8 Moving parts 11 Support edge 12, 13 Chambers 14, 18 Slide section 17, 32 joint 19, 19'' handling head 22 Flattening section 24 O-ring 25 Locking mechanism 33 Lance 34 Pneumatic Actuator

Claims

1. A device (1) for manufacturing a cable harness, comprising: a presentation plate (2), on the front of which the cables (4) of the cable harness can be placed; a handling element (5, 5', 5'') for handling the cables (4) of the cable harness, the handling element (5, 5', 5'') being magnetically attached or attachable to the presentation plate (2); Equipped with the device (1) having a pneumatic system capable of creating an air cushion between the handling element (5, 5', 5'') and the presentation plate (2); A device (1).

2. 2. The device (1) according to claim 1, characterized in that the presentation plate (2) is designed to be air-fillable.

3. 3. Device (1) according to claim 1 or 2, characterized in that the pneumatic system is designed to increase the adhesion of the handling elements (5, 5', 5'') to the presentation plate (2), optionally by means of a vacuum.

4. The device (1) according to any one of claims 1 to 3, characterized in that the handling elements (5, 5', 5'') each comprise a front handling part (7) and a rear movable part (8).

5. The device (1) according to any one of claims 4 to 6, characterized in that the presentation plate (2) is designed as a perforated plate, which has a number of holes (6) through which compressed air can pass.

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

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

8. 8. The device (1) according to any one of the preceding claims, characterized in that each handling element (5, 5', 5''), in particular the movable part (8) of the handling element (5, 5', 5''), has a pneumatic connection capable of being supplied with compressed air.

9. 9. A device (1) according to any one of claims 1 to 8, characterized in that it has a positioning system (30) for moving the handling elements (5, 5', 5'') to a desired position, the positioning system for moving the handling elements (5, 5', 5'') comprising a positioning head (31) with a coupling (32) for mechanical coupling, in which a pneumatic coupling, preferably designed as a lance (33), is integrated into the coupling (32).

10. 10. The device (1) according to claim 8 or 9, characterized in that the movable part (8) of the handling element (5, 5', 5'') has a connecting part (17) with a spherical outer contour for the mechanical connection, the outer contour having a spherical flattening (22), and inside the connecting part (17) an insertion opening (23) is arranged which is sealed or can be sealed by an O-ring (24).

11. A device (1) according to any one of claims 1 to 10, in particular, characterized in that the handling part (7) attached or attachable to the presentation plate (2) has a handling head (19) adjacent to and rotatably connected to the slide part (18), and the bearing for the rotatable connection between the handling head (19) and the slide part (18) has a locking mechanism (25) for fixing the handling head in a desired rotational position.

12. 12. The device (1) according to claim 11, characterized in that the locking mechanism is operatively connected to a pneumatic system such that the rotation lock by the locking mechanism (25) can be released by the pneumatic system and the handling head (19) can be freely rotated.

13. A method for producing a cable harness, in particular using a device (1) according to any one of claims 1 to 12, comprising: The housing is attached and the cables (4) required for the cable harness are placed on the presentation plate (2) using handling elements (5, 5', 5''), which are magnetically attached on the presentation plate (2), the handling elements (5, 5', 5'') are moved over the presentation plate (2) by introducing compressed air, whereby an air cushion is created between the handling elements (5, 5', 5'') and the presentation plate (2); method.

14. 14. The method according to claim 13, characterized in that after completion of a single-step movement of the handling elements (5, 5', 5'') first the compressed air supply is disconnected from the handling elements (5, 5', 5'') and then the mechanical coupling of the handling elements (5, 5', 5'') is released.

15. 15. Method according to claim 13 or 14, characterized in that if the handling element (5, 5', 5'') needs to be held adhesively on the presentation plate (2), a vacuum is created between the handling element (5, 5', 5'') and the presentation plate (2).

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