Systems and methods for design and production of wire harnesses

Abstract

Systems and methods are described for manufacturing a wire harness using a harness or ruler board with multiple mounting points, each capable of receiving a peg or other component. A circuit board is provided that receives wire harness design information and uses that information to control a set of light sources, such as LEDs, on or adjacent to the harness board. The light sources are preferably arranged at or near the mounting points and are selectively illuminated based on the received design data to indicate locations of the different elements of the wire harness design.

Description

Attny Dkt No. 104498.0002PCTSYSTEMS AND METHODS FOR DESIGN AND PRODUCTION OF WIRE HARNESSESField of the Invention

[0001] The field of the invention is wire harness manufacturing.Background

[0002] The following description includes information that may be useful in understanding the present invention. It is not an admission that any of the information provided herein is prior art or relevant to the presently claimed invention, or that any publication specifically or implicitly referenced is prior art.

[0003] Wire harnesses are assemblies of electrical wires and connectors used to transmit power and signals in various applications, such as automotive, industrial, aerospace, and consumer electronics. Wire harness manufacturing generally involves connecting wires, terminals, and other components to create a system that allows current to flow.

[0004] Manufacturing first requires gathering requirements and specifications of the wire harness and creating a diagram of the components including how they are laid out relative to one another. Typically, the diagram is designed using computer-aided design (CAD) software. The diagram may include, for example, information on wire types, wire lengths, insulation, routing paths, connectors, and other components of the assembly. Designing a wire harness is a detailed and methodical process that involves several phases or stages to ensure that the wire harness is suitable for its intended application and accounts for electrical requirements, physical space constraints, environmental conditions, safety standards, and manufacturability.

[0005] Once designed, the wire harness can be assembled during the forming phase, which typically involves the manual routing of wires on a harness or router board according to the specific design or blueprint. An exemplary router board 100 is shown in Figure 1 which comprises a plurality of pegs 102, each of which is disposed a mounting point 104.

[0006] The wire harness board provides a platform to arrange and secure individual wires in a specific pattern. It allows for clear visualization and manual routing of wires to ensure the wire harness is constructed properly before further steps like crimping, soldering, or insulating, forAttny Dkt No. 104498.0002PCTexample. It also allows a harness design to be verified including that the lengths of wires are correct and so forth.

[0007] After the wires are laid out, groups of wires may be bundle and terminals added to the wires as required. The assembled wire harness can then be tested to ensure it is properly assembled and meets the required performance criteria.

[0008] In such manual process, the use of a ruler board requires constant comparison of the ruler board with information within the drawing to determine how to route the wires. This often leads to errors and inefficiencies during the forming phase, due to incorrect calculations, incorrect decisions, a lack of expertise, and so forth.

[0009] While a 1 : 1 scale board could be used to represent an easier forming process due to the full morphology being displayed as well as the right location of the different elements within the formboard, converting dimensional drawings to a 1 : 1 scale representation can be a very complex and time-consuming manual process that can have a high probability for mistakes.

[0010] All publications identified herein are incorporated by reference to the same extent as if each individual publication or patent application were specifically and individually indicated to be incorporated by reference. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.

[0011] Thus, there is still a need for improved wire harness manufacturing systems and methods that reduces or eliminates the amount of information required to correctly locate a component during the forming process of the wire harness.Summary of the Invention

[0012] The inventive subject matter provides apparatus, systems and methods for manufacturing a wire harness that utilize a harness board comprising a plurality of light sources disposed on or adjacent to the harness board. In preferred embodiments, the plurality of light sources are each disposed at or near one of the mounting points of the harness board.Attny Dkt No. 104498.0002PCT

[0013] The systems and methods can utilize a circuit board that can receive information about the wire harness design and selectively illuminate at least some of the light sources to indicate a location of the different components of the design. In some embodiments, the light sources can also be sued to indicate elements that are defined based on the morphology and conditions of the design itself.

[0014] Various objects, features, aspects, and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.Brief Description of the Drawings

[0015] Figure 1 illustrates one embodiment of a harness board having a plurality of mounting points from which a peg or other projection extends.

[0016] Figure 2 illustrates a schematic of one embodiment of a system for manufacturing a wire harness.

[0017] Figures 3A-3B illustrate a front view and a side view, respectively, of one embodiment of a harness board comprising a plurality of light sources.

[0018] Figure 4 illustrates an example of a CAD file for a harness design.

[0019] Figure 5 illustrates one embodiment of a method for manufacturing a wire harness.

[0020] Figure 6 illustrates one embodiment of a method for assembling a wire harness.Detailed Description

[0021] Throughout the following discussion, numerous references may be made regarding servers, services, interfaces, portals, platforms, or other systems formed from computing devices. It should be appreciated that the use of such terms is deemed to represent one or more computing devices having at least one processor configured to execute software instructions stored on a computer readable tangible, non- transitory medium. For example, a server can include one or more computers operating as a web server, database server, or other type of computer server in a manner to fulfill described roles, responsibilities, or functions.Attny Dkt No. 104498.0002PCT

[0022] The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus, if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.

[0023] Figure 2 illustrates one embodiment of a system 200 for manufacturing a wire harness. System 200 comprises a circuit board 210 that is electrically connected to a plurality of light sources 220. The circuit board 210 may comprise a Raspberry Pi circuit board or could comprise any other commercially suitable circuit board capable of receiving information and causing one or more of the light sources 220 to illuminate based on the received information. Preferred circuit boards comprise a processor, a memory, and one or more input / output ports to receive and transmit information or signals.

[0024] As shown, the circuit board 210 may be connected to an input device 230 such as a scanner or other device used to obtain a code or other information. In the drawing, the scanner may scan a barcode or value that is specific to (and may point to) a specific drawing formboard or harness design, such as shown in Figure 4. In this manner, using the input device 230, for example, the circuit board 210 is configured to receive information about the wire harness design after scanning the barcode or value which can be linked to a database of saved designs. The specific design or information about the design may be transmitted to the circuit board 210.

[0025] Based on the received information, the circuit board 210 is configured to selectively illuminate one or more of the light sources 220. It is contemplated that the light sources 220 can be illuminated based on their relative position to one another and on a harness board. It is further contemplated that based on the received information, the circuit board 210 can selectively illuminate specific ones of the light sources 220 and in specific colors, brightnesses, patterns (e.g., blinking), and so forth. Thus, different ones of the light sources 220 maybe illuminated differently or not at all based on the received design.

[0026] It is preferred that the plurality of light sources 220 comprises light-emitting diodes (LEDs), which may be disposed in a series along a strip. Of course, other types of light sourcesAttny Dkt No. 104498.0002PCTcould be used without departing from the scope of invention herein. The light sources 220 may be single color but are preferably RGB light sources, such that the light sources 220 can be illuminated in a variety of colors.

[0027] Other components could be connected to the circuit board 210 such as a light sensor 240, a switch 250, and so forth.

[0028] Figures 3A-3B illustrate a front view and a side view, respectively, of one embodiment of a harness board 301 having a plurality of light sources 320 disposed on the board 301. The harness board 301 preferably comprises a plurality of mounting points 304 disposed on the board 301 which can each receive a peg, pin, or other component 302. The pegs or pins can be used to hold wires in the correct positions, for example, and prevent them from moving during assembly or testing of the wire harness. As shown, the mounting points 304 may be arranged in a grid pattern or could be disposed in a different arrangement.

[0029] The harness board 310 could be formed from one or more materials including, for example, plywood, plastic, or metal, and generally has a flat surface. The harness board 310 may comprise various markings, labels, or grids that can help to guide the correct placement and routing of wires or other components.

[0030] In preferred embodiments, the light sources 320 are arranged on the harness board 301 such that each light source 320 is disposed at or near one of the mounting points 304. Other light sources may be disposed between mounting points, for example. In still other embodiments, it is contemplated that light sources 320 may be embedded within the harness board 310 and disposed at specific points.

[0031] As shown in Figure 3B, each of the plurality of mounting points 304 may comprise a light source 320, with each light source 320 being electrically connected to a circuit board 310 that controls the light sources 320. Control of the light sources based on the received information about the harness design is described above with respect to Figure 2 and not repeated here. As discussed above, the circuit board 310 is configured to selectively illuminate one or more of the light sources 320 based on the received information.Attny Dkt No. 104498.0002PCT

[0032] In some embodiments, the plurality of mounting points 304 may each comprise an aperture in the harness board 301 (such as shown in Figure 3B).

[0033] The light sources 320 can be disposed in strips 322, and are preferably individually addressable, such that the circuit board 310 can selectively illuminate specific ones of the light sources 320 and in specific colors using the electronics such as shown in Figure 2 to control the light sources 320. This can be used, for example, to indicate the precise location of different components of the wire harness within a drawing formboard based on the received file with the information containing which light source to illuminate which color. It is contemplated that simply scanning a barcode can cause the light sources to illuminate accordingly to the received information without additional interaction required. This advantageously will drastically reduce the need to analyze the design drawing to determine the location of each component.

[0034] As an example, it is contemplated that the circuit board 310 can receive a file after scanning a barcode or otherwise obtaining a specific value linked to the file. The file preferably contains information about which light sources 320 should be illuminated and in which color. It is contemplated that each barcode could represent a specific stage or component to be installed on the harness board 301. Different barcodes may be scanned at each step in the process of assembling the wire harness until the wire harness is completed.

[0035] Figure 5 illustrates an exemplary flowchart detailed one embodiment of a method of manufacturing a wire harness using the inventive subject matter discussed herein.

[0036] Figure 6 illustrates an embodiment of a method for assembling a wire harness. In step 610, a harness board is provided that comprises a plurality of mounting points such as that shown in Figure 3A. Each of the plurality of mounting points can receive a peg or other component Preferably, the harness board comprises a plurality of light sources electrically connected to a circuit board. In some embodiments, the plurality of light sources are arranged on the harness board such that each light source is disposed at one of the plurality of mounting points.

[0037] It is contemplated that each of the plurality of mounting points may comprise one of the plurality of light sources.Attny Dkt No. 104498.0002PCT

[0038] The plurality of light sources may comprise a series of LEDs disposed on a strip or otherwise connected to the circuit board. The LEDs may be disposed in series and preferably comprise RGB LEDs that allow for a variety of colors to be illuminated and controlled by the circuit board.

[0039] In step 620, a code can be scanned or entered such as by using an input device, and the code can be transmitted to the circuit board. The code can be used, for example, in step 630 to retrieve a fde concerning a drawing formboard of a wire harness design that is specific to that code and that instructs the circuit board to selectively illuminate some of the light sources. The file may be retrieved from a server or device.

[0040] In step 640, a first set of the light sources of the harness board can be selectively illuminated in a first color based on the retrieved information. It is contemplated that a second set of the light sources may be illuminated in a second color based on the retrieved information.

[0041] As used herein, and unless the context dictates otherwise, the term "coupled to" is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms "coupled to" and "coupled with" are used synonymously.

[0042] In some embodiments, the numbers expressing quantities of ingredients, properties such as concentration, reaction conditions, and so forth, used to describe and claim certain embodiments of the invention are to be understood as being modified in some instances by the term “about.” Accordingly, in some embodiments, the numerical parameters set forth in the written description and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by a particular embodiment. In some embodiments, the numerical parameters should be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of some embodiments of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as practicable. The numerical values presented in some embodiments of the invention mayAttny Dkt No. 104498.0002PCTcontain certain errors necessarily resulting from the standard deviation found in their respective testing measurements.

[0043] Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints and open-ended ranges should be interpreted to include only commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.

[0044] As used in the description herein and throughout the claims that follow, the meaning of “a,” “an,” and “the” includes plural reference unless the context clearly dictates otherwise. Also, as used in the description herein, the meaning of “in” includes “in” and “on” unless the context clearly dictates otherwise.

[0045] The recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value with a range is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g. “such as”) provided with respect to certain embodiments herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.

[0046] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member can be referred to and claimed individually or in any combination with other members of the group or other elements found herein. One or more members of a group can be included in, or deleted from, a group for reasons of convenience and / or patentability. When any such inclusion or deletion occurs, the specification is herein deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.Attny Dkt No. 104498.0002PCT

[0047] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C .... and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc.

Claims

Attnv Dkt No. 104498.0002PCTCLAIMSWhat is claimed is:

1. A system for manufacturing a wire harness, comprising:a harness board comprising a plurality of mounting points which can each receive a peg or other component;a circuit board configured to receive information about a wire harness design;a plurality of light sources electrically connected to the circuit board; andwherein the circuit board is configured to selectively illuminate one or more of the light sources based on the received information.

2. The system of claim 1, wherein the light sources are arranged on the harness board such that each light source is disposed at one of the plurality of mounting points.

3. The system of claim 1, wherein each of the plurality of mounting points comprises a light source, and wherein each of the light sources is electrically connected to the circuit board.

4. The system of claim 1, wherein the plurality of mounting points are arranged in a grid pattern.

5. The system of claim 1, wherein the plurality of light sources comprises a series of lightemitting diodes (LEDs).

6. The system of claim 5, wherein the plurality of light sources comprises RGB light sources, such the light sources can be illuminated in a variety of colors.

7. The system of claim 1, wherein the received information instructs the circuit board to turn on specific ones of the light sources and in specific colors.

8. The system of claim 7, wherein different ones of the light sources may be illuminated in different colors.

9. The system of claim 1, wherein the plurality of mounting points each comprises an aperture in the harness board.Attny Dkt No. 104498.0002PCT10. The system of claim 1, wherein the received information comprises a scanned value, and wherein the scanned value points to a specific drawing formboard.

11. A method for assembling a wire harness, comprising:providing a harness board comprising a plurality of mounting points which can each receive a peg or other component, wherein the harness board comprises a plurality of light sources electrically connected to a circuit board;scanning or entering a code and transmitting the scanned code to the circuit board; retrieving information concerning a drawing formboard based on the scanned code; and selectively illuminating a first set of the light sources of the harness board in a first color based on the retrieved information.

12. The method of claim 11, wherein the retrieved information comprises a wire harness design.

13. The method of claim 11, wherein the plurality of light sources are arranged on the harness board such that each light source is disposed at one of the plurality of mounting points.

14. The method of claim 11, further comprising selectively illuminating a second set of the light sources of the harness board in a second color based on the retrieved information.

15. The method of claim 11, wherein each of the plurality of mounting points comprises one of the plurality of light sources.

16. The method of claim 11, wherein the plurality of light sources comprises a series of lightemitting diodes (LEDs).

17. The method of claim 16, wherein the plurality of light sources comprises RGB light sources, such the light sources can be illuminated in a variety of colors.

18. The method of claim 11, wherein the plurality of mounting points are arranged in a grid pattern.

19. The method of claim 11, wherein the plurality of mounting points each comprises an aperture in the harness board.Attny Dkt No. 104498.0002PCT20. The method of claim 11, wherein the scanned code points to a specific drawing formboard stored on a server or device.

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