Wire Harness Branch Formation Using Sliding Wire Pullout Control
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Solution Overview
Problem
Existing manufacturing apparatuses for wire harnesses with branch shapes require manual operations for forming and determining branch shapes, making it difficult to automate these processes.
Innovation Solution
An apparatus with sliding portions, tip-end connectors, and a control portion to automatically pull out and bundle electric wires, forming branch shapes through controlled pulling and tape winding operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual operations are used for forming and determining branch shapes, then the manufacturing process can be performed with simple equipment, but automation is difficult and reliance on skilled operators increases
Solution Approach 1:
The manufacturing apparatus is divided into multiple independent sliding portions, each capable of individually pulling out electric wires. This segmentation allows each portion to perform a specific function (pulling, positioning, bundling) independently, enabling automated branch shape formation while keeping each component relatively simple in structure
Solution Approach 2:
The sliding portions are designed to move dynamically along rails to pull out electric wires by predetermined distances. This dynamic movement capability allows the apparatus to automatically adjust wire lengths and form branch shapes without complex manual intervention, achieving automation through controlled mechanical motion
2Productivity
If skilled operators perform operations based on experience, then manufacturing precision can be maintained, but productivity is limited and human intervention is required
Solution Approach 1:
The apparatus pre-determines the pulling distances for each sliding portion based on the desired branch shape. By calculating and setting these distances in advance, the system eliminates the need for operators to measure and adjust wires manually during production, significantly improving productivity while maintaining precision through automated control
Solution Approach 2:
The invention replaces manual mechanical operations with an automated control system that manages multiple sliding portions. The control unit automatically coordinates the movement of each sliding portion to pull out wires and form branches, substituting human skill-based operations with automated mechanical control, thereby increasing productivity and reducing operation time
Data Source
AI summary
An apparatus for manufacturing wire harness includes a plurality of sliding portions provided to move in a straight line, wherein each is mounted with a tip-end connector to which an electric wire that can be pulled out is connected; a moving tape winding mechanism (branch formation portion) configured to selectively bundle the plurality of electric wires being pulled out by the plurality of sliding portions to form a branch; and a control portion configured to control a pulling-out amount of the electric wires due to the movement of the sliding portions and branching operations due to the moving tape winding mechanism (branch formation portion).