Adaptive Bundle Gripping End Effector for Wire Harness Assembly
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Solution Overview
Problem
Bundling and tying of wires in complex electronic and electromechanical systems, such as aircraft or vehicle wiring, is highly labor-intensive due to the need for creating and maintaining orderly harness arrangements, which is inefficient and time-consuming.
Innovation Solution
A bundle gripping tool with a support ring and a rotatable snare ring, where snare cables are engaged between the rings to encircle the bundle axis, allowing for efficient handling and consolidation of wire bundles through a mechanism that transitions from an open to a closed position, enabling the snare cables to transition from a convex to a concave configuration to securely hold the bundle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual bundling and tying methods are used for wire harnesses, then flexibility in handling complex wiring patterns is maintained, but labor intensity and time consumption increase significantly
Solution Approach 1:
The gripping mechanism is divided into distinct functional segments: a support ring that provides structural framework, a snare ring with multiple snare cables for individual wire engagement, and an actuator system. This segmentation allows each component to perform its specific function efficiently while reducing overall operational complexity
Solution Approach 2:
The snare ring is nested within the support ring structure, with snare cables extending from the snare ring to engage individual wires. This nested configuration allows the gripping mechanism to consolidate multiple wires into a unified bundle while maintaining a compact device form factor
2Reliability
If a closed gripping structure is used to secure wire bundles, then bundle stability is improved, but access to the bundle axis for insertion becomes difficult
Solution Approach 1:
The jaw is designed to rotate between open and closed positions, transforming the gripping structure from an inaccessible closed form to an accessible open form. This dynamic configuration allows the same structure to provide both stable securing when closed and easy insertion access when open
Solution Approach 2:
The jaw is positioned in the open state during the insertion phase to provide unobstructed access to the bundle axis, then transitions to the closed state after insertion to provide stable securing. This sequential positioning ensures that insertion and securing requirements are met at appropriate operational stages
3Force
If snare cables are positioned to encircle the bundle axis for secure gripping, then gripping force is improved, but the ability to expose the bundle axis for insertion is reduced
Solution Approach 1:
The snare ring rotates with the jaw between open and closed positions. When the jaw is open, the snare cables are positioned to allow bundle axis access; when the jaw closes, the snare ring rotates to position the snare cables for encirclement and gripping. This dynamic repositioning resolves the contradiction between access and gripping force
Solution Approach 2:
The mechanism alternates between two states: an open state where snare cables are repositioned to expose the bundle axis for insertion, and a closed state where snare cables encircle the bundle axis to provide gripping force. This periodic transition ensures both insertion accessibility and secure gripping are achieved at appropriate times
Data Source
AI summary
A bundle gripping tool has a support ring sector 12a extending from a handle 11 and a jaw 12b pivotally mounted to the handle opposing the support ring sector 12a. The jaw is rotatable from an open position to a closed position wherein the jaw 12b and support ring sector 12a form a circular support ring 12 concentric to a bundle axis 14. The jaw exposes a first open sector accessing a central aperture in the open position. A snare ring 22 is supported on the jaw 12b in the open position and rotatable on the support ring 12 in the closed position and has a second open sector 34 wherein in an unrotated position of the snare ring at least partially aligns the second open sector with the first open sector exposing the central aperture. A plurality of snare cables 40 are engaged between the support ring and the snare ring with a first set of attachment points and second set of attachment points relatively positioned whereby each of the plurality of snare cables partially encircles the bundle axis in the closed and rotated position and exposes the bundle axis in the unrotated and open position. An actuator 48 is configured to open and close the jaw and rotate the snare ring with the jaw in the closed position.