Automated Cable Harness Production System
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Solution Overview
Problem
The production of cable harnesses with branched structures in the motor vehicle industry is inefficient due to the high variety of types and variants, requiring significant manual labor and lengthy production times, despite existing semi-automated and automated methods.
Innovation Solution
A modular, fully automated system comprising two parts: the first part prepares individual line elements by cutting, stripping, and contacting, while the second part assembles the branched cable set using a manipulator and transport system to distribute and fix the elements in a predetermined structure, enabling fully automated production without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual assembly methods are used for cable harnesses with high variety of types and variants, then flexibility in handling diverse cable configurations is improved, but production time and labor intensity increase significantly
Solution Approach 1:
The cable harness production system is divided into multiple independent processing stations (cutting, stripping, contacting, assembling, testing) that can process different cable elements in parallel. Each station handles specific tasks, allowing the system to manage diverse cable configurations efficiently while maintaining high throughput and reducing overall production time.
2Extent of automation
If semi-automated processes are used for cable harness production, then some automation benefits are achieved, but significant manual intervention is still required
Solution Approach 1:
The processing stations are designed with universal, interchangeable modules that can handle multiple cable types and configurations through programmable control. The same basic station structure can be reconfigured via software to accommodate different cable harness variants, achieving full automation without requiring complex manual reconfiguration for each product type.
3Quantity of substance
If customized cable sets are produced after customer order receipt, then inventory costs are reduced, but delivery time requirements become more difficult to meet
Solution Approach 1:
The system performs preliminary preparation of cable elements (cutting, stripping, contacting) and stores them in buffer stations ready for assembly. When an order is received, the pre-prepared elements can be quickly assembled into the final cable harness configuration, enabling rapid customization and delivery without maintaining finished goods inventory.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The system (2) functions for the automated production of a cable set (3), which has a branched structure formed by multiple individual line elements (22). The system (2) has two parts (4, 6), wherein, in a modular set-up, multiple first processing stations (A to D) are arranged in the first part (4) and multiple second processing stations (E to K) are arranged in the second part (6). In the first part (4), an automatic preparation of the individual line elements (22) occurs, which are then collected in a buffer station (D) at the end of the first part (4). In the second part (6), the prepared individual line elements (22) are combined to form the cable set (3). For this, the line elements (22) are introduced into connector housings (76) in a connector station (E), and transferred to second transporters (48), and the branched structure of the cable set (3) is then formed by means of these second transporters (48) by moving along second tracks (50). In this spread branched structure, inter alia, a fixing of the line elements (22) to one another occurs in a fixing station (G).