Automated Wire Processing System for Aircraft Harnesses
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Solution Overview
Problem
Automated wire assembly systems are impractical for fabricating aircraft wiring harnesses due to the need for high reliability and precise, repeatable processes, which traditional methods struggle to achieve effectively.
Innovation Solution
A wire processing system comprising a wire transport with a retaining tray, springs, and wire retainers that hold wires in a straight orientation, combined with modular processing stations for tasks like stripping, electrical component delivery, and soldering, allowing for efficient and precise wire harness manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual wire assembly methods are used, then flexibility and adaptability are maintained, but manufacturing precision and reliability are insufficient
Solution Approach 1:
The automated wire assembly system is divided into discrete modular processing stations, each performing a specific function (wire cutting, stripping, connector attachment, soldering). This segmentation allows the system to achieve high manufacturing precision through specialized automation at each station while managing overall system complexity through modularity and standardized interfaces between stations.
2Productivity
If traditional manual methods are used, then device complexity is low, but productivity and manufacturing efficiency are insufficient
Solution Approach 1:
The system performs preliminary actions by pre-positioning wires in a wire guide, pre-cutting and pre-stripping insulation before connector attachment. This sequence of preliminary automated actions prepares the wire assembly for subsequent connector attachment and soldering operations, significantly increasing productivity while maintaining controlled automation levels through standardized processing steps.
3Reliability
If high automation is implemented, then productivity increases, but manufacturing precision and reliability become harder to maintain
Solution Approach 1:
The automated processing stations incorporate feedback mechanisms including sensors to detect wire position, connector alignment, and processing completion. This feedback enables real-time adjustments to maintain manufacturing precision and reliability despite the complexity of automated operations, ensuring consistent quality through closed-loop control at each processing station.
4Manufacturing precision
If manual assembly is used, then system complexity is low, but manufacturing precision and repeatability are insufficient
Solution Approach 1:
The system achieves high connector attachment precision by controlling critical parameters including wire position in the wire guide, connector placement location, attachment force, and temperature for soldering. These parameter changes are precisely controlled at each automated station to ensure repeatable high-precision manufacturing, overcoming the limitations of manual assembly while managing implementation complexity through standardized parameter control.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables improved reliability and efficiency in wire harness production by ensuring precise wire handling and processing, addressing the limitations of traditional methods and enhancing the manufacturing process for aircraft wiring.
Implementation Method 1
one or more springs, wherein the one or more wire retainers are coupled together and coupled to the one or more springs
Data Source
AI summary
A system is provided for wire processing. The wire processing system may include a wire transport, a processing station that may provide wire to the wire transport, a processing station that may move an electrical component threaded onto the wire, and a processing station that may move the electrical component to a position on the wire for further processing.