Wire Harness Work Board Orientation for Faster Routing And Inspection
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Solution Overview
Problem
The existing wire harness manufacturing systems face inefficiencies in operational efficiency due to limited access to work boards during manufacturing, requiring manual placement of subassemblies and time-consuming defect analysis in automated examination technologies.
Innovation Solution
A wire harness manufacturing system with a conveyance device that circulates work boards through multiple processing zones, including a raiser to set boards upright for improved access, a routing processing device for automated subassembly placement, and an examination device that displays error information with wire harness images to quickly identify connection defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If work boards are conveyed constantly in an obliquely standing up state, then access to the work board is limited to one side, but operational efficiency decreases depending on the process
Solution Approach 1:
The work board's orientation is changed dynamically during the manufacturing process. The work board is set to an obliquely standing up state during routing processing to improve access from one side, and then returned to a horizontal state for examination processes. This dynamic state change allows the system to optimize for different operational requirements at different stages, resolving the contradiction between ease of operation and productivity.
2Reliability
If appearance examination is performed by directly connecting connector to examination device, then examination can be conducted, but operational efficiency potentially decreases
Solution Approach 1:
The work board is returned to a horizontal state before examination processes, with the connector oriented upward. This preliminary positioning action enables direct connection between the connector and examination device without requiring complex positioning or reorientation during examination, thereby maintaining examination capability while improving operational efficiency.
3Productivity
If automated examination technology is used to compare input-output results, then examination time is reduced, but defect location analysis remains time-consuming
Solution Approach 1:
The examination device provides visual feedback by displaying captured images of the wire harness appearance alongside examination results. When defects are detected, the system shows the specific location in the image, enabling operators to quickly identify and analyze defect locations without manual tracing or extensive analysis time, thus resolving the contradiction between examination speed and defect analysis time.
Data Source
AI summary
A wire harness manufacturing system including a plurality of processing zones and configured to manufacture a wire harness by using a subassembly including a plurality of electrical lines to each of which a connection component is attached includes a conveyance device provided along the plurality of processing zones and including: work boards in a number at least corresponding to the number of the plurality of processing zones; a circulation conveyer configured to sequentially convey each work board in a horizontal state from an upstream side to a downstream side on a downstream conveyance path along the plurality of processing zones and then return the work board from the downstream side to the upstream side on an upstream conveyance path; and a raiser configured to set the work board to a stand-up state in which one of edge parts extending in a conveyance direction of the work board is positioned on an upper side of the other edge part in the work board, and to set the work board in the stand-up state to the horizontal state.