Augmented Reality Vision System for Wire Harness Assembly
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Solution Overview
Problem
The manual production of wire harnesses is inefficient due to the use of paper-based instructions, which require technicians to split their attention, take more time, and can be confusing, making it difficult to maintain focus on the assembly process.
Innovation Solution
An augmented reality vision system is introduced, comprising a head-mounted display system with a mobile application that provides interactive instructions, allowing technicians to view task information and wire maps without needing to put down the wire harness, using a camera system for verification and real-time image analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If paper-based instructions are used for wire harness assembly, then the manufacturing process is simple and inexpensive, but the technician's productivity is reduced due to the need to frequently refer to and flip through paper packets
Solution Approach 1:
The patent uses a digital copy of the instruction manual in the form of a mobile application that replicates the paper packet's functionality. The mobile device displays instructions, wire harness diagrams, and assembly steps, eliminating the need for physical paper packets while maintaining the same informational content. This digital copy can be viewed without physically handling the wire harness, thereby improving assembly speed.
Solution Approach 2:
The patent replaces the mechanical system of physical paper packets with a digital system using a mobile application. Instead of manually flipping through pages and physically referencing instructions, the system uses electronic display, search, and navigation functions. This substitution eliminates the mechanical limitations of paper-based reference and enables faster, more efficient assembly operations.
2Ease of operation
If paper instructions are referenced during assembly, then the technician can follow assembly steps, but the technician's attention is split between the wire harness and the paper instructions
Solution Approach 1:
The mobile application creates a digital copy of the instruction manual that can be accessed without physically handling the wire harness. The technician can view instructions, diagrams, and assembly steps on the mobile device screen while maintaining focus on the assembly task, eliminating the need to split attention between paper packets and the wire harness.
Solution Approach 2:
The system allows technicians to search for and access specific instructions before needing them during assembly. The mobile application enables proactive retrieval of wire harness diagrams, assembly steps, and troubleshooting information, so that when the technician needs to perform a specific task, the relevant information is already accessible, reducing delays.
3Reliability
If paper packets are used for assembly instructions, then the system is simple to implement, but the instructions are difficult to read and can be confusing
Solution Approach 1:
The patent replaces the mechanical paper-based instruction system with a digital mobile application system. The electronic display can provide enhanced visual clarity, zoomable diagrams, and structured information presentation that is difficult to achieve with paper. The digital system can also include interactive elements, search functions, and customizable views that improve instruction clarity and reduce confusion.
Solution Approach 2:
The mobile application can change the presentation parameters of the instructions dynamically. The system can adjust text size, diagram resolution, color coding, and information hierarchy based on the specific assembly task and user preferences. This flexibility allows the same instruction set to be presented in multiple optimized formats, improving clarity and reducing misunderstandings.
Data Source
AI summary
A method and apparatus for an augmented reality vision system. A first input selecting a branch is received. Task information associated with a wire harness containing the branch is retrieved based on the first input. A second input requesting information related to inserting a wire is received. A plug map of a plug of the branch of the wire harness is generated based on the second input and using the task information associated with the wire harness. The plug map is displayed on a display system. A location of a selected wire is indicated in the plug map.