Wiring Harness Connector Staging Device for Robotic Assembly
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Solution Overview
Problem
Automated assembly of vehicle wiring harnesses is hindered by the complexity of consistently locating and removing adhesive tape from electrical connectors, which is challenging for robotic installers.
Innovation Solution
A wiring harness system with a staging device featuring a flexible-member, such as a quarter-round ribbed-spacer, that removably retains electrical connectors within a cavity, ensuring they are presented in a predetermined position for easy robotic assembly, reducing the need for adhesive tape removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive tape is used to protect electrical connectors during handling, then connector protection is improved, but automation complexity increases due to the need for tape removal
Solution Approach 1:
The patent removes the adhesive tape protection method entirely and replaces it with a rigid protective housing that encapsulates the electrical connector. This extraction of the tape removal step eliminates the complexity associated with automated tape removal while maintaining connector protection throughout handling and installation processes.
Solution Approach 2:
The protective housing is designed as a separate modular component that can be easily attached to and removed from the electrical connector. This segmentation allows the protection mechanism to be independently managed without interfering with the connector's electrical functions or requiring complex integrated systems.
2Stability of the object's composition
If adhesive tape is used to secure connectors, then temporary retention is achieved, but precise positioning for robotic assembly becomes difficult
Solution Approach 1:
The rigid protective housing serves as an intermediary structure between the electrical connector and the handling/assembly system. It provides a standardized interface with precise geometric features that enable robotic grippers to reliably locate and manipulate the connector, eliminating positioning variability inherent in adhesive tape applications.
Solution Approach 2:
The patent transitions from the variable parameters of adhesive tape (application pressure, coverage, bonding strength) to fixed geometric parameters of the rigid housing (dimensions, tolerances, feature locations). This parameter change enables consistent, repeatable positioning with tolerances suitable for automated assembly.
3Ease of operation
If manual handling methods are used for wiring harness installation, then flexibility is maintained, but productivity decreases
Solution Approach 1:
The rigid protective housing provides multiple functions: it protects the connector during storage and handling, provides precise positioning for robotic assembly, and serves as a manipulation interface for both automated and manual operations. This multi-functionality enables a single design to support both high-speed automation and flexible manual handling when needed.
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 allows for precise and repeatable positioning of electrical connectors, facilitating automated installation by reducing the complexity of connector location and removal, thereby enhancing the efficiency of robotic assembly processes.
Implementation Method 1
The flexible-member is configured to be in compressive contact with the electrical-connector when inserted within the cavity. The flexible-member is configured to removably retain the electrical-connector within the cavity.
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3B
AI summary
A wiring-harness (10) includes an electrical-connector (12) and a staging-device (14). The staging-device (14) has a cavity (16) defining a flexible-member (18) in compressive contact with the electrical-connector (12). The flexible-member (18) is configured to removably retain the electrical-connector (12) within the cavity (16). The cavity (16) locates the electrical-connector (12) in a predetermined-position (32) within the staging-device (14), such that the electrical-connector (12) is presented to an assembler in the predetermined-position (32). The staging-device (14) is particularly useful in automated, i.e. robotic, installation of the wiring-harness (10).