Wire Harness Assembly With OCR-Guided Connector Insertion
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Solution Overview
Problem
The existing methods for manufacturing wire harnesses are inefficient and prone to mis-wiring due to the complexity of the process, requiring significant skill, time, and cost, with conventional systems failing to provide clear indications for wire insertion and often relying on manual input and custom setups for each connector type.
Innovation Solution
A computer-implemented system that includes a wire marking reader, a two-axis translation stage, and a cassette tray to automate the identification and error-free insertion of wires into connector pin-hole receptacles, using illumination from below to guide the user and integrating optical character recognition for accurate wire ID detection, reducing human error and setup costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hand-assembly methods are used with magnifiers and optical fibers, then wire insertion accuracy can be improved, but assembly time and device complexity increase significantly
Solution Approach 1:
The patent replaces manual mechanical assembly operations with an automated system that uses a camera to capture connector images, processes them through image recognition algorithms, and displays guidance information on a screen. This substitution eliminates the need for physical magnifiers and manual optical fiber manipulation while maintaining high insertion accuracy and significantly reducing assembly time.
Solution Approach 2:
The patent creates a visual copy or representation of the connector and wire positions through image capture and processing. The system captures an image of the actual connector, processes it to identify pin locations and wire routes, and displays this processed visual information on a screen to guide the assembler, replacing the need for direct visual inspection through magnifiers.
2Manufacturing precision
If custom optical fiber systems are implemented for each connector type, then insertion guidance accuracy improves, but setup cost and complexity increase
Solution Approach 1:
The patent implements a universal image processing system that can handle multiple connector types without requiring custom optical fiber configurations for each. The system uses a standard camera and image recognition algorithm that adapts to different connector geometries by capturing and processing images of the specific connector being assembled, eliminating the need for connector-specific optical setups.
Solution Approach 2:
The patent replaces complex mechanical optical fiber routing systems with a software-based image recognition and display system. Instead of physically configuring optical fibers for each connector type, the system captures images, processes them through algorithms, and displays the results on a screen, significantly reducing setup complexity while maintaining guidance accuracy.
3Loss of time
If manual wire identification and typing is required, then system cost is reduced, but assembly time and error rate increase
Solution Approach 1:
The patent implements an automated wire identification system where the camera captures images of the connector and wire markings, the image recognition algorithm automatically identifies wire positions and routes, and the system displays the information without requiring manual typing or input. The system serves itself by automatically processing and presenting the necessary guidance information, eliminating manual labor while reducing overall system complexity through automation.
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 system significantly reduces assembly time and costs by ensuring accurate wire insertion with high efficiency, minimizing mis-wiring errors, and allowing for portable and flexible use across various applications, including aviation, automotive, and other industries.
Implementation Method 1
integrating optical character recognition for accurate wire ID detection
Implementation Method 2
using illumination from below to guide the user
Data Source
AI summary
The device, system and process of the present invention provides a means and method for assembly of wire harnesses. The present invention comprises at least a wire viewer module, a machine vision and optical character recognition module, a cassette tray platform, designed to receive and hold in place a cassette tray, having one or more receptacles designed to receive and hold in place a wire harness connector, having multiple pin-hole cavities illuminated from below or behind by a light source mounted on a two-axis translation stage or gantry to identify a cavity for wire insertion. Moreover, the present invention may further comprise a portable, computer-implemented system capable of executing a series of automated process steps designed to identify wire markings and guide the insertion of identified wires into wire harness connector pin-hole receptacles for assembly of a wire harness.