Robotic Wiring Harness Layout With Automated Cutting and Labeling
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Solution Overview
Problem
Existing procedures for laying out wiring harnesses are resource-intensive and error-prone, particularly for bespoke and low-volume configurations, requiring manual cutting and labeling of wire segments.
Innovation Solution
A robotic system comprising a support table, a robotic arm, a wire dispenser, and a system controller that automates the process of cutting, labeling, and arranging wire segments along predefined routes using wire routing pins, reducing manual intervention and increasing precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cutting and laying out of wire segments is used, then flexibility in handling bespoke configurations is maintained, but error rate increases and resource consumption increases
Solution Approach 1:
The patent replaces manual mechanical operations (cutting, measuring, laying out wires) with an automated robotic system that uses computer-controlled mechanisms. The robotic arm with end effector automatically performs wire cutting, labeling, and positioning operations, eliminating human error while maintaining precision for bespoke configurations.
Solution Approach 2:
The system enables self-service automation where the robotic system autonomously completes the entire wire harness assembly process without continuous human intervention. The controller manages the robotic arm movements, wire dispensing, cutting, and labeling operations automatically based on the predefined layout specifications.
2Productivity
If automated robotic system is used, then productivity increases and error rate decreases, but device complexity increases
Solution Approach 1:
The robotic system is designed with multi-functionality to handle various wire harness configurations through a single integrated platform. The robotic arm with interchangeable end effectors can perform multiple operations (cutting, labeling, positioning) and accommodate different wire types, layouts, and component configurations, reducing the need for multiple specialized devices.
Solution Approach 2:
The system divides the complex wire harness assembly process into discrete, manageable segments: wire dispensing, cutting, labeling, and positioning. Each function is handled by a specialized component (wire dispenser, robotic arm with end effector, labeler) that works in coordinated sequence, making the overall complex system manageable through functional decomposition.
3Manufacturing precision
If precise wire routing is required for bespoke configurations, then manufacturing precision increases, but time consumption increases
Solution Approach 1:
The system performs preliminary actions by pre-programming the wire harness layout specifications and routing paths before production begins. The controller is provided with detailed layout data that defines exact wire routes, connection points, and positioning requirements, allowing the robotic system to execute precise operations without real-time decision-making delays.
Solution Approach 2:
The patent replaces time-consuming manual measurements and positioning with automated robotic positioning controlled by computer coordinates. The robotic arm moves wires to precise locations based on pre-calculated positions, achieving high manufacturing precision while significantly reducing the time required compared to manual layout processes.
Data Source
AI summary
A robotic system for laying out a specified wiring harness. A robotic arm is configured to arrange a plurality of wire segments along the harness support surface. A system controller is configured to direct the robotic arm to arrange each of the plurality of wire segments on the harness support surface along a specified wire route. A preparation device can label one or both ends of each wire segment as they are being laid out on the support surface. The labeler can automatically apply adhesive labels as flags at selected locations along the length of the wire segment. In a method of making a wiring harness, the robotic arm positions pins on a harness support surface to define wire routes and then arranges at least one wire segment on the harness support surface along each of the wire routes.