Cable Holder Layout for Faster Wiring Harness Connector Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual assembly of connector housings in electrical vehicle wiring harnesses is complex and difficult to automate due to the intricate movements required for orienting and positioning electrical terminals and their associated wires, especially with varying terminal types and lengths, leading to high costs and long lead times in production.
Innovation Solution
A cable holder system that allows pre-sorting and holding electrical wires on a form board, enabling manual, semi-automated, or automated assembly by simplifying the insertion process through clamping and guiding mechanisms, independent of terminal orientation, and allowing unobstructed access for robots or workers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual assembly of connector housings is performed with intricate terminal positioning, then assembly precision can be maintained, but assembly time and complexity increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-orienting and pre-positioning electrical terminals in a specific orientation (e.g., all terminals facing the same direction) before the assembly process. This preliminary preparation eliminates the need for time-consuming orientation checks and adjustments during assembly, allowing workers to quickly and accurately position terminals in connector housings without compromising precision.
2Productivity
If automation is attempted for terminal assembly, then productivity can be increased, but the complexity of automation systems and cost increase due to handling varied terminal orientations
Solution Approach 1:
The patent changes the orientation parameter of all electrical terminals to a uniform state before assembly. By standardizing terminal orientation (e.g., all terminals facing upward or in the same direction), the system simplifies the automation process, allowing robotic pick-and-place machines to efficiently assemble terminals without complex sensors or adjustment mechanisms to handle varied orientations.
3Productivity
If pick-and-place machines are used for terminal insertion, then assembly speed improves, but terminal orientation verification becomes time-consuming
Solution Approach 1:
The patent implements preliminary action by ensuring all electrical terminals are pre-oriented in a consistent direction before being fed to the pick-and-place machine. This preliminary orientation eliminates the need for the machine to verify or adjust terminal orientation during assembly, maintaining high assembly speed while eliminating the time-consuming verification step.
4Adaptability or versatility
If different types of electrical terminals with varying lengths are assembled, then product versatility is achieved, but automation becomes difficult and manual handling complexity increases
Solution Approach 1:
The patent applies parameter changes by standardizing the orientation parameter across all terminal types regardless of their varying lengths or configurations. By orienting all terminals in the same direction and position, the system maintains ease of operation for both manual and automated assembly while still accommodating different terminal types, as the standardized orientation simplifies handling and insertion processes.
Data Source
Figure 1~2
Figure 3~4
Figure 5~8
AI summary
The invention relates to a cable holder (10) for the manual and/or automated assembly of a connector housing of an electrical vehicle wiring harness with electrical conductors (910) assembled with electrical terminals, wherein by means of the cable holder (10) a plurality of conductors (910) for the and/or for assembly of the connector housing can be pre-sorted and preferably held on a wiring harness form board (0) in such a way that the connector housing can be and preferably is assembled with the conductors (910) in a targeted manner.