Manual Cable Insertion Guide Slot for Harness Manufacturing
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Solution Overview
Problem
Existing machines for manufacturing electrical harnesses face challenges in modularity, complexity, and cost due to the variety of connectors, cables, and terminals, leading to underutilization of subsystems and increased return on investment, while also requiring precise and gentle handling to avoid deformation of cable lugs and alteration of crimp resistance.
Innovation Solution
A manual insertion device with a longitudinal tunnel and guide slot allows for precise and efficient insertion of cable terminations into connectors, featuring a gripping mechanism that alternates between open and closed positions, controlled by an actuator activated by the operator, minimizing mechanical contact and tension, and includes optical means for cable orientation and color recognition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated gripping means are used to handle cable terminations, then insertion speed improves, but mechanical contact and tension deform the terminals and compromise crimp strength
Solution Approach 1:
The operator manually performs the delicate operation of inserting the termination into the guide slot, eliminating the need for automated gripping means that would cause deformation. The human operator's dexterity allows precise handling without mechanical contact forces that would compromise terminal integrity.
Solution Approach 2:
The guide slot acts as an intermediary structure that receives the termination directly from the operator's hand and guides it to the correct position. This intermediary mechanism allows transfer without requiring automated grippers to contact and manipulate the delicate termination.
2Reliability
If manual insertion is used to preserve termination integrity, then terminal deformation is minimized, but insertion speed decreases
Solution Approach 1:
The guide slot is pre-positioned and the operator is trained to insert the termination directly into the slot in one smooth motion. This preliminary preparation of the insertion path eliminates the need for multiple adjustment steps, maintaining high speed while preserving terminal integrity through manual insertion.
3Manufacturing precision
If specialized machines are used for harness assembly, then precision insertion is achieved, but machine complexity and cost increase
Solution Approach 1:
The complex automated insertion system is extracted and replaced with a simple guide slot structure. The precision function is achieved through the geometric design of the guide slot itself rather than through complex automated positioning mechanisms, significantly reducing machine complexity.
Solution Approach 2:
The guide slot serves as a simple intermediary structure that provides precise positioning guidance. Instead of using complex automated systems to achieve precision, the guide slot's geometry alone ensures accurate placement of the termination into the connector.
4Adaptability or versatility
If modularity is increased to accommodate variety of connectors and cables, then adaptability improves, but machine cost and complexity increase
Solution Approach 1:
The guide slot is designed as a universal receiving structure that can accommodate different types of terminations and cables. Rather than having specialized mechanisms for each connector type, the same guide slot structure handles various configurations, providing adaptability without increasing complexity.
Data Source
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Figure 8~11
AI summary
Machine for manufacturing an electrical harness resulting from the assembly of a plurality of cables, each end of a cable being formed of a portion of wire covered with insulation (11), and a termination (12, 13, 14), without insulation, said machine comprising means for inserting said termination onto a terminal or into a socket of a connector and, disposed upstream of said insertion means, at least one device for manually inserting the cables accessible to an operator, characterized in that said manual insertion device is formed by a longitudinal tunnel (2) consisting of a casing (20, 25, 25a, 26, 26a, 27, 27a) delimiting an internal space (29) in which at least one means for gripping the end (10) of the cable (1) circulates, alternating between an open position and a closed position, and an external space (28) accessible to the operator,said tunnel (2) being transversely sectioned from end to end by a guide slot (21) such that, when the operator inserts the end of the cable (10) into the guide slot (21) while holding the termination (12, 13, 14) in the external space (28), the gripping means (3, 31, 32) closes on the part of the end of the cable covered by the insulation (11).