Multi-axis Support Cart for Wiring Harness Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Technicians face fatigue and inconsistency when assembling wiring harnesses due to the bulkiness and heaviness of automated tools, which require one hand to hold and position wires while the other operates the tool, leading to suboptimal stripping and crimping results.
Innovation Solution
A multi-axis support cart with a base on wheels, telescoping risers for vertical movement, and a turntable for rotational alignment, allowing for easier handling and positioning of automated tools, reducing technician fatigue and ensuring consistent results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If automated tools are used for wire stripping and crimping, then manufacturing precision and consistency are improved, but device weight and bulk increase making them difficult to handle
Solution Approach 1:
The automated tool is segmented from its support system. The tool head is separated and mounted on an adjustable arm that can be positioned independently, allowing the heavy automated tool to be supported by the cart structure rather than requiring manual support by the technician.
Solution Approach 2:
An adjustable arm and mounting mechanism serve as an intermediary between the technician and the automated tool. This intermediary structure supports the tool's weight and provides positioning capabilities, freeing the technician's hands while maintaining control over the automated tool's location and orientation.
2Manufacturing precision
If automated tools are used for wire stripping and crimping, then manufacturing precision is improved, but ease of operation deteriorates due to bulkiness and weight
Solution Approach 1:
The tool mounting system is made dynamic and adjustable rather than fixed. The arm can be positioned at multiple locations, angled at different orientations, and adjusted during operation to accommodate various wire harness configurations and technician preferences, greatly improving ease of operation.
Solution Approach 2:
The tool positioning capability is extended into multiple spatial dimensions through the adjustable arm mechanism. The tool can be positioned not only in horizontal locations but also at various heights and angles, providing three-dimensional adjustment freedom that simplifies operation for different task requirements.
3Ease of operation
If hand tools are used for wire stripping and crimping, then ease of operation is maintained, but manufacturing precision and consistency deteriorate
Solution Approach 1:
The system merges the advantages of both hand tools and automated tools. The automated tool provides consistent stripping and crimping results, while the adjustable mounting system provides the ease of operation and positioning flexibility characteristic of hand tools, combining both benefits into a single integrated system.
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 multi-axis support cart facilitates safe and efficient use of automated tools, reducing technician fatigue and ensuring consistent and uniform results in wiring harness assembly by enabling precise positioning and operation without requiring manual handling of heavy tools.
Implementation Method 1
a piston coupled between the base and the support surface facilitating movement of the support surface along the third axis
Implementation Method 2
wheels (e.g., casters) coupled to the base facilitating movement of the base along the first plane
Data Source
AI summary
A multi-axis support cart includes a base having a longitudinal axis and a second axis defining a first plane with wheels coupled to the base facilitating movement of the base along the first plane. Coupled to the base is at least one telescoping riser extending along a third axis orthogonal to the first plane. A support surface is coupled to the at least one telescoping riser and configured on a second plane parallel to the first plane with a piston coupled between the base and the support surface facilitating movement of the support surface along the third axis. A turntable coupled to the support surface receives a device/tool and provides rotational movement for the device/tool about the third axis.