Cobot Wire Harness Taping for Accurate Datum Alignment
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Solution Overview
Problem
In the manufacturing of high-voltage wiring harnesses for electrified vehicles, the existing methods for securing the wiring with tape often result in lost datum integrity, leading to costly rework or rejection due to human error in applying tape at precise locations along the vehicle.
Innovation Solution
A taping machine system that combines human intervention with a collaborative robot (cobot) to accurately position and tape high-voltage wiring harnesses, using a multi-axis robot with an end effector to engage the harness, a taper for applying tape, and a shuttle to move the harness between positions, ensuring precise alignment and consistent taping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If human operators manually measure and apply tape at specified datums, then the process is flexible and adaptable, but datum integrity is lost leading to misalignment between taped support features and mounting structures
Solution Approach 1:
The patent replaces manual measurement and taping operations with an automated taping machine system that uses mechanical positioning and robotic application. The machine incorporates a positioning system with scales and a robotic arm that automatically applies tape at precise datums, eliminating human measurement errors while maintaining manufacturing precision.
Solution Approach 2:
The taping machine system is designed to be self-positioning and self-taping. The machine automatically positions itself along the wiring harness using the positioning system, calculates datum locations based on mounting structure specifications, and applies tape without requiring continuous human intervention or measurement, thereby preserving datum integrity throughout the process.
2Manufacturing precision
If additional tape is applied to compensate for lost datum integrity, then mounting alignment can be achieved, but manufacturing costs increase
Solution Approach 1:
The taping machine performs preliminary positioning and taping actions at the correct datums before installation. By accurately positioning the tape at the specified datums during manufacturing, the system ensures that no additional tape or adjustment is needed during installation, preventing both material waste and cost increase.
3Reliability
If wiring harnesses are rejected due to datum misalignment, then quality control is maintained, but productivity decreases
Solution Approach 1:
The taping machine incorporates a feedback system that continuously monitors positioning accuracy and datum alignment. The positioning system provides real-time feedback on the machine's location along the wiring harness, allowing the control system to make precise adjustments and ensure that tape is applied at the correct datums, thereby maintaining quality control without rejecting parts.
Data Source
AI summary
A method of taping a wiring harness includes longitudinally positioning a wiring harness relative to a taping machine, taping a first datum along the wiring harness with a taper, robotically positioning the wiring harness from the first datum to a second datum, and taping the second datum along the wiring harness with the taper. The resultant taped wiring harness may be used in high voltage vehicle applications, for example.