Cable Fork Harness Assembly for Automated Bundling and Tensioning
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Solution Overview
Problem
The manual assembly of cable harnesses for motor vehicles is time-consuming, labor-intensive, and costly, often requiring two people to tension and fix the cable bundles, which limits efficiency and increases expenses.
Innovation Solution
A device with a controllable cable fork equipped with a clamping mechanism and a movement device that automates the bundling and tensioning of cables, allowing for partial automation of the assembly process, including the use of an automatic winding machine for wrapping the cable bundle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly is used for cable harnesses, then flexibility and simplicity are maintained, but productivity and labor efficiency deteriorate
Solution Approach 1:
The assembly device is divided into separate functional modules: cable forks for individual cable management, clamping mechanisms for bundling, and movement devices for positioning. Each module operates independently but coordinates through the control unit, allowing the system to maintain simplicity while achieving automated high-speed assembly
Solution Approach 2:
The cable forks are designed with universal applicability to handle different cable types and configurations. The movement devices can position multiple cable forks simultaneously, and the control unit coordinates various functions (clamping, positioning, bundling) through a single integrated system, improving productivity without proportionally increasing complexity
2Loss of time
If manual tensioning and securing of cable bundles is performed, then equipment costs remain low, but loss of time and labor intensity increase
Solution Approach 1:
The clamping mechanisms are pre-positioned on the cable forks and automatically engage to bundle cables as they are inserted. The movement devices pre-position the cable bundles before the wrapping operation, eliminating the need for manual tensioning and securing steps, thus reducing assembly time while maintaining manufacturing simplicity through automated sequences
3Productivity
If automated clamping and movement mechanisms are introduced, then productivity improves, but device complexity increases
Solution Approach 1:
The control unit serves as an intermediary that coordinates the clamping mechanisms and movement devices. It receives input signals, processes the required actions, and sends control signals to the appropriate mechanisms, enabling automated high-productivity assembly while keeping the individual mechanisms relatively simple and manageable
Solution Approach 2:
Manual mechanical operations (tensioning, bundling, positioning) are replaced with automated clamping mechanisms actuated by drives and controlled by a control unit. This substitution increases productivity by eliminating manual labor while the modular design keeps the overall device complexity manageable through standardized components
Data Source
Figure 1a~1c
Figure 2a~2b
Figure 3a~3c
AI summary
The invention relates to a device for assembling cable harnesses with at least one controllable cable fork (10, 10a) for receiving several cables (31), wherein the cable fork (10, 10a) has at least one clamping mechanism (13) for bundling and fixing the cables (31) into a cable bundle (30), which is connected to a drive (15) for force transmission, and wherein a movement device (16) for moving the cable fork (10, 10a) is provided such that a path for the cable bundle (30) can be changed for tensioning the cable bundle (30). The invention further relates to a system with such a device and an assembly method.