Projector-Based Wire Insertion Alignment
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Solution Overview
Problem
Assembling cable harnesses is a labor-intensive process, particularly due to the manual insertion of dozens of wires into connectors, where existing systems rely on mechanically moving a laser beam for illumination, lacking an efficient method for alignment and orientation.
Innovation Solution
A wire insertion apparatus with a projector that projects alignment dots and illuminates pin locations on a connector based on its position and orientation, assisted by a computer device for user input and connector schematics, allowing for precise alignment and illumination of pin locations without mechanical parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a mechanical laser beam moving system is used for illumination, then the system can provide dynamic lighting guidance, but the system complexity and mechanical failure risk increase
Solution Approach 1:
The patent replaces the mechanical laser beam moving system with a projector that uses optical projection technology. The projector projects graphical information including alignment dots and illumination indicators directly onto the connector and surrounding area, eliminating the need for mechanical moving parts while maintaining dynamic guidance capability through software-controlled projection patterns.
Solution Approach 2:
The projector creates a visual copy or representation of the connector's pin locations and wire routing paths by projecting graphical information onto the physical workspace. This optical copy provides guidance without requiring physical mechanical movement, allowing operators to see illuminated indicators at each pin location that correspond to the actual connector geometry.
2Manufacturing precision
If manual wire insertion is performed without alignment assistance, then the process is simpler in terms of equipment, but the insertion precision and orientation accuracy decrease
Solution Approach 1:
The projector displays alignment dots and graphical information before the wire insertion process begins, allowing operators to pre-position wires and understand the required orientation and routing paths. The system provides preliminary visual guidance that prepares the operator for accurate insertion without requiring complex mechanical positioning devices during the actual insertion act.
Solution Approach 2:
The projector uses different colors or illumination patterns to indicate various pin locations, wire types, and insertion priorities. By projecting colored or differently illuminated indicators at each pin location, the system provides intuitive visual differentiation that guides operators to insert wires into the correct positions with proper orientation, enhancing precision through visual coding rather than mechanical guidance.
3Productivity
If dozens of wires are inserted manually without systematic guidance, then the equipment requirement is lower, but the labor intensity and time consumption increase significantly
Solution Approach 1:
The projector divides the complex task of inserting dozens of wires into manageable segments by illuminating and indicating one pin location or a small group of pin locations at a time. The graphical information displays sequential or prioritized guidance, allowing operators to focus on inserting wires into specific illuminated areas rather than attempting to manage all pin locations simultaneously, thereby improving efficiency through segmented visual instruction.
4Illumination intensity
If alignment dots are projected onto the connector directly, then the alignment information is highly visible, but the connector surface may be obscured or contaminated
Solution Approach 1:
The projector projects alignment dots and graphical information onto the connector and surrounding workspace area, utilizing the three-dimensional space around the connector rather than requiring direct contact with the connector surface. By projecting light patterns that appear to be on or near the connector without physically touching it, the system maintains high visibility while avoiding contamination risks associated with physical alignment tools or markers that would contact the connector surface.
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
Facilitates quick and accurate wire insertion into connectors by providing graphical information for alignment and illumination, reducing labor intensity and mechanical reliance, enabling easy differentiation of pin locations through customizable illumination dots.
Implementation Method 1
a projector held in the projector mount projects graphical information onto the connector
Data Source
AI summary
A system for assisting in the assembly of a cable harness may include a wire insertion apparatus that includes a frame that defines a connector mounting location; a projector mount attached to the frame and positioned so that a projector held in the projector mount projects graphical information onto a connector held by the mounting location; and the projector. The system may also include a computer device in communication with the projector and comprising a module configured for: projecting, via the projector, a plurality of alignment dots onto the connector; moving the alignment dots based on a first user input; receiving a second user input that the alignment dots are aligned and, based on the second user input, determining a position and orientation of the connector; and illuminating, via the projector, one or more pin locations of the connector based on the position and orientation of the connector.