Wire Harness Assembly Board With In-Process Connection Verification
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Solution Overview
Problem
Existing wire harness assembly processes require manual assembly and late-stage testing, leading to costly and labor-intensive fault detection and correction of electrical connections.
Innovation Solution
A wiring assembly board equipped with microcomputers that operate independently to initiate test signals through specific wires, allowing early identification of swapped or incorrectly connected wires during assembly, using wireless communication and test connectors that replace mechanical grips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If testing is performed after wire harness assembly, then the testing process is simplified, but fault detection is delayed requiring extensive rework
Solution Approach 1:
The patent implements preliminary testing during the assembly process by integrating test connectors and microcomputers that can perform electrical continuity tests on individual wires as they are being connected. This allows faults to be detected early when only some wires are connected, avoiding the need to disassemble the entire harness for rework.
Solution Approach 2:
The system incorporates real-time feedback through microcomputers that continuously monitor electrical connections during assembly. When a fault is detected, the system provides immediate feedback to the assembler, allowing for instant correction rather than waiting for final testing after complete assembly.
2Ease of operation
If traditional mechanical grips are used to secure wires, then the assembly process is simple, but electrical connections cannot be tested during assembly
Solution Approach 1:
The patent merges the mechanical gripping function with the electrical testing function by integrating test connectors that both secure wires mechanically and provide electrical contact for continuity testing. This combination eliminates the need for separate testing equipment and allows simultaneous mechanical securing and electrical verification.
Solution Approach 2:
The test connectors serve multiple functions: they mechanically secure the wires to the assembly board, provide electrical contact points for continuity testing, and interface with the microcomputer system for automated testing. This multi-functionality reduces the number of separate components needed.
3Productivity
If assembly boards are designed for specific wire harness configurations, then assembly is streamlined, but adapting to different designs requires rewiring
Solution Approach 1:
The patent uses parameter changes in the form of software configuration on the microcomputers to adapt to different wire harness designs. Rather than physically reconfiguring the assembly board for each design variant, the system changes its operational parameters through software, allowing the same hardware to support multiple configurations.
Solution Approach 2:
The assembly board with integrated microcomputers and test connectors is designed to be universally applicable to different wire harness configurations. The system can be reprogrammed to accommodate various wiring diagrams and connection patterns, eliminating the need for dedicated assembly boards for each design variant.
4Ease of operation
If manual wire matching to circuit diagrams is performed, then assembly flexibility is maintained, but assembly time and labor costs increase
Solution Approach 1:
The system provides real-time feedback during assembly by automatically testing electrical connections as wires are connected. This immediate feedback eliminates the need for manual verification against circuit diagrams, reducing assembly time while maintaining flexibility through programmable test sequences that can be adjusted for different designs.
Solution Approach 2:
The assembly system performs self-verification through automated electrical continuity testing. Rather than requiring the assembler to manually check each connection against a diagram, the microcomputer system automatically tests and verifies connections, freeing the assembler to focus on the physical assembly tasks while the system handles verification.
Data Source
Figure 1~2
Figure 3
AI summary
A wiring assembly board (1) for assembling a wire harness (4). The wire harness (4) comprises a plurality of wires (11) connected between a plurality of wiring connectors (3), each connector (3) comprising an array of wire terminals (12). The wiring assembly board (1) comprises an assembly surface (2) and a plurality of test connectors (8) provided on the assembly surface (2). Each test connector (8) is for connection to a respective wiring connector (3) and comprises an array of test terminals (13) for establishing an electrical connection with the respective array of wire terminals (12) once the wiring (3) and test connectors (8) have been connected. A microcomputer (7) is associated with each test connector (8) and comprises an interface (14) for individually transmitting or receiving test signals though each test terminal (13) of the respective test connector (8).