3D Work Vehicle Wiring Harness Assembly for Branch Orientation Accuracy
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Solution Overview
Problem
Existing methods for manufacturing wiring harnesses in work vehicles often result in improper configuration and orientation of branches, leading to stress on the harness and potential malfunctions due to the use of 2D models that fail to accurately capture the 3D requirements of the wiring harness configuration, causing misalignment and interference with other components.
Innovation Solution
A method utilizing a 3D model of the wiring harness with breakout branches arranged at specific angles relative to the main harness branch and non-parallel, non-perpendicular orientations is used, along with a tool board assembly with adjustable wire supports and I/O connector holders to accurately position and orient the branches, ensuring correct routing and attachment to electronic devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a 2D model is used for manufacturing wiring harnesses, then the manufacturing process is simple, but the wiring harness configuration and orientation are improper, leading to stress and potential malfunctions
Solution Approach 1:
The patent transitions from using a 2D model to a 3D model for manufacturing wiring harnesses. The 3D model enables proper spatial configuration and orientation of the main harness branch and multiple breakout harness branches, ensuring they are positioned at correct angles and locations in three-dimensional space rather than being constrained to a flat plane. This dimensional change resolves the contradiction by providing manufacturing precision while maintaining process feasibility through systematic tool board assembly.
2Manufacturing precision
If a 3D model with multiple dimensions is used for wiring harness configuration, then the positioning accuracy is improved, but the device complexity increases
Solution Approach 1:
The tool board assembly is segmented into multiple independent components, each responsible for supporting specific portions of the wiring harness. The tool board includes a base with multiple wire supports positioned at different locations, heights, and angles, allowing each support to be independently configured. This segmentation enables precise positioning of the main harness branch and breakout harness branches without requiring a monolithic complex device, as each component can be separately adjusted and assembled.
Solution Approach 2:
The wire supports and connector holders in the tool board assembly are designed with adjustable properties, allowing their positions, heights, and orientations to be modified during the manufacturing process. This dynamic capability enables the tool board to adapt to different wiring harness configurations while maintaining manufacturing precision, reducing the need for multiple fixed complex devices for different scenarios.
3Ease of manufacture
If breakout harness branches are routed at improper orientations, then the manufacturing process is simpler, but stress on the harness increases and malfunctions occur
Solution Approach 1:
The 3D model is created beforehand to define the optimal configuration, orientation, and routing paths for the main harness branch and all breakout harness branches before the actual manufacturing process begins. This preliminary action ensures that all branches are positioned at correct angles and locations, preventing stress and potential malfunctions. The pre-planned 3D configuration guides the assembly process, making it straightforward to follow the predetermined optimal paths rather than requiring complex real-time adjustments during manufacturing.
Data Source
AI summary
A method of manufacturing a wiring harness for a work vehicle includes providing a tool board assembly having a tool board base, wire supports extending from the tool board base each having a wire holder on a top end thereof distal from the tool board base, and a plurality of I/O connector holders extending from the tool board base and each having an angularly adjustable connector mount. A wiring harness is provided having a main harness branch and a plurality of breakout harness branches extending off the main harness branch, with each breakout harness branch having an I/O connector at an end thereof. The wiring harness is configured, via arranging thereof on the tool board assembly, to arrange the breakout harness branches at a plurality of breakout angles relative to the main harness branch and at oblique-angle orientations that are non-parallel and non-perpendicular to the tool board base.