Assisted Wire Assembly Guiding Device
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Solution Overview
Problem
The assembly of cable harnesses, particularly the connection of wires to connectors, is challenging due to miniaturization of components, requiring skilled workers and prone to human error, and existing automated systems are expensive and inflexible, struggling with various wire configurations and small terminal handling.
Innovation Solution
A robot or machine-assisted manual assembly method using a guiding device with a predetermined connecting sequence, where the device automatically aligns channels with connector cavities, and the user manually guides wire ends into place, reducing errors and improving efficiency while maintaining flexibility and lower costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fully automated assembly systems are implemented, then productivity and precision are improved, but device complexity and cost increase significantly
Solution Approach 1:
A guiding device serves as an intermediary between manual assembly and full automation. The guiding device includes positioning structures and guides that assist workers in correctly positioning wires and terminals without requiring complex automated manipulation systems. This mediator provides the precision benefits of automation while keeping the overall system simpler and more cost-effective.
2Adaptability or versatility
If miniaturization of terminals and connectors is pursued, then product sophistication is improved, but ease of operation deteriorates due to difficulty in reading cavity numbers and grasping wires
Solution Approach 1:
The connector assembly process is segmented into distinct zones: a magnification zone with optical aids for reading cavity numbers, a guiding zone with physical guides for wire positioning, and an assembly zone with positioning structures. This segmentation allows workers to perform each sub-task more easily despite the miniaturized components, breaking down the difficult operation into manageable steps with dedicated assistance for each.
3Device complexity
If manual assembly is used, then flexibility and lower cost are maintained, but productivity and quality are reduced due to human error
Solution Approach 1:
The guiding device provides self-service assistance through built-in positioning structures, guides, and magnification features that automatically help the worker achieve correct positioning. The system serves itself by providing the necessary guidance and support mechanisms that reduce reliance on worker skill and attention, thereby improving consistency and reducing errors while maintaining manual operation simplicity.
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
An assisted method of electrically connecting a plurality of wires to a connector comprises the steps of securing the connector comprising a plurality of cavities onto a base; loading a predetermined connecting sequence onto the controller of a guiding device, wherein each step of the connecting sequence includes the location of one or more of the cavities; preparing a plurality of wires that each correspond to the respective steps of the connecting sequence; starting the connecting sequence to automatically move the guiding device to align one or more channels with the respective one or more cavities that correspond to the first step of the connecting sequence; and repeating the following steps until the end of the connecting sequence: manually guiding each of the one or more ends of the wire corresponding to the connecting sequence through the corresponding channel of the guiding device and into the aligned cavity to electrically connect the wire to the connector; releasing the wire from the guiding system; and automatically aligning the one or more channels of the guiding device with the one or more cavities corresponding to the next step of the connecting sequence.