Robotic Wiring Harness Branch Routing With Wire Spool Pay-Out
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Solution Overview
Problem
The manual routing and securing of automotive wiring harnesses in vehicle assembly plants is labor-intensive, ergonomically challenging, and costly, often requiring complex redesigns and additional components to address ergonomic issues.
Innovation Solution
A robotic method and apparatus that utilize a gripping mechanism on a robotic arm to wrap, route, and secure wiring harness branches within a vehicle, using calculated lengths and various attachment devices like P-clamps, fir tree fasteners, and annular disks to automate the process, reducing manual labor and ergonomic concerns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual routing and securing of wiring harnesses is performed by human assembly operators, then the process can be completed with simple equipment, but labor intensity and ergonomic issues increase significantly
Solution Approach 1:
A wire spool is introduced as an intermediary component that the robotic arm manipulates to pay out wiring harness branches. The spool serves as a mediator between the robotic gripping mechanism and the wiring harness, enabling automated routing while maintaining simplicity in the overall system design.
Solution Approach 2:
The patent replaces manual mechanical operations with a robotic arm equipped with a gripping mechanism. The robotic system automates the routing and securing operations that were previously performed manually, reducing labor intensity while managing equipment complexity through standardized components.
2Ease of operation
If additional components such as non-standard wiring channels are added to address ergonomic issues, then operator comfort improves, but design complexity and cost increase
Solution Approach 1:
The patent eliminates ergonomic issues by replacing manual wiring harness installation with an automated robotic system. This substitution removes the need for ergonomic redesigns of wiring channels and routing paths, as the robotic arm can navigate complex paths without human physical constraints.
Solution Approach 2:
The patent extracts the routing complexity from the human operator and transfers it to the robotic system. The robotic arm handles the complex routing operations through programmed motion, while the wiring channels themselves can remain standard and simple in design.
3Adaptability or versatility
If standardized wiring channels and routing paths are used for all vehicle models, then design complexity is reduced, but adaptability to different vehicle configurations decreases
Solution Approach 1:
The patent introduces dynamic adaptability through the robotic arm, which can adjust its motion paths and routing strategies based on the specific vehicle model and electronic content requirements. The robotic system dynamically adapts to different configurations without requiring physical redesign of wiring channels.
Solution Approach 2:
The patent enables adaptability through parameter changes in the robotic control system. By modifying motion parameters, routing paths, and securing locations in the control program, the same robotic system and standardized wiring channels can accommodate different vehicle models and electronic content configurations.
4Productivity
If robotic automation is implemented for wiring harness installation, then labor costs and installation time are reduced, but the complexity of the installation system increases
Solution Approach 1:
The wire spool acts as a simple intermediary that bridges the robotic arm and the wiring harness, enabling automated pay-out of wire branches. This intermediary simplifies the robotic system's task by providing a straightforward mechanism for wire dispensing, reducing the overall system complexity while maintaining high productivity.
Solution Approach 2:
The robotic arm with gripping mechanism serves multiple functions: it picks up the wire spool, maneuvers it to pay out the wiring harness branch, positions the wire, and secures it with clips. This multi-functionality consolidates several operations into a single robotic system, improving productivity while managing complexity through integration.
Data Source
AI summary
A method of installing an electrical wiring harness in a vehicle, wherein the electrical wiring harness has at least one branch circuit terminated by an electrical connector includes the steps of wrapping the at least one branch circuit around a wire spool configured to be picked up and manipulated by a robotic arm having a gripping mechanism, placing the electrical wiring harness within the vehicle; and grasping the wire spool with the gripping mechanism while simultaneously moving the robotic arm and rotating the wire spool with the gripping mechanism to pay out a desired length of the at least one branch circuit. An apparatus for performing this method and an electrical wiring harness well suited for use with this method is also described herein.