Rotating Wiring Harness Assembly Cell for Safe Robot-Human Throughput
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Solution Overview
Problem
The existing assembly process for vehicle wiring harnesses, particularly high voltage cables, is labor-intensive and inefficient due to the need for manual application of tape and body clips, with robots and human operators unable to work simultaneously, leading to compromised efficiency and high costs for multi-board assembly processes.
Innovation Solution
A semi-automated wiring harness assembly cell with a movable robot and reconfigurable assembly stations allows simultaneous operation of manual and automated tasks by separating human operators from the automation zone, enabling a single robot to efficiently operate on multiple boards through a guide rail system and rotating assembly boards for seamless transitions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robot is positioned at a fixed static location adjacent the harness assembly board to perform automated assembly operations, then the automation of taping and cable tie application is improved, but the human operator must pause and withdraw from the assembly board, compromising the efficiency and utilization of both the human operator and the robot
Solution Approach 1:
The assembly board is made rotatable to dynamically change its orientation between manual operator zone and robot zone, allowing seamless transition between manual and automated operations without pausing either process
Solution Approach 2:
The assembly process is segmented into distinct manual operations and automated operations that can occur simultaneously at different times by rotating the assembly board between zones
2Extent of automation
If a dedicated robot is assigned to each assembly board to perform automated assembly operations, then the automation capability is improved, but the cost of automation for larger scale assembly processes involving more than one assembly board becomes prohibitively expensive
Solution Approach 1:
A single robot is designed to perform multiple functions by servicing multiple assembly boards through rotation, eliminating the need for dedicated robots at each station and reducing overall automation cost
3Productivity
If human operators and robots operate simultaneously on an assembly board, then the efficiency is improved, but safety risks arise requiring operators to withdraw while robots operate
Solution Approach 1:
The rotatable assembly board creates dynamic separation between human and robot work zones, allowing simultaneous operation in different spatial locations while maintaining safety
Solution Approach 2:
The system transitions from two-dimensional planar work space to three-dimensional utilization by rotating the assembly board vertically, creating separate operational planes for human and robot
Data Source
AI summary
A wiring harness assembly cell includes an automation zone housing a robot for performing automated assembly operations on a series of wiring harness assembly boards. A plurality of wiring harness assembly stations is located about the automation zone, each including one or more wiring harness assembly boards holding the wiring harnesses. Manual operator zones are located outside the automation zone that are associated with the wiring harness assembly stations. The wiring harness assembly stations are reconfigurable between a first configuration in which a first wiring harness assembly board faces the manual operator zone such that it is accessible to a manual operator, and a second configuration in which it faces the automation zone such that it is accessible to the robot. The robot is moved within the automation zone between a plurality of assembly locations where it accesses and operates on the respectively the plurality of wiring harness assembly stations.