Wire Harness Assembly with Connector Cups for Flexible Branch Routing
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Solution Overview
Problem
Current wire harness manufacturing apparatuses struggle to automatically manufacture various types of wire harnesses with different branch shapes and connector types, as they require complex configurations to switch holding portions and routing mechanisms.
Innovation Solution
A wire harness manufacturing apparatus featuring a plurality of connector cups, a sub-harness mounting plate, slide portions, and a connector transfer mechanism, which allows for automatic manufacturing by detachably attaching connectors and routing electric wires in a linear movement to form branch shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a manufacturing apparatus uses multiple holding members arranged on a flat wiring board to accommodate various harness types, then the adaptability to different connector types and branch shapes is improved, but the device complexity increases due to the need to switch holding portions and routing mechanisms
Solution Approach 1:
The apparatus divides the wiring board into multiple regions, each region containing holding members for specific connector types. This segmentation allows different harness types to be accommodated in different regions without requiring complex switching mechanisms, as the system can simply select which region to use based on the harness type being manufactured
Solution Approach 2:
The apparatus employs movable holding members that can be repositioned along the wiring board. This dynamic capability allows the same physical infrastructure to adapt to different harness configurations without requiring complete reconfiguration or replacement of holding portions, thereby reducing device complexity while maintaining versatility
2Ease of operation
If manual operations are used to perform manufacturing tasks, then the ease of operation is improved, but the productivity decreases due to time-consuming manual assembly
Solution Approach 1:
The apparatus is designed to automatically perform wire routing, connector attachment, and harness assembly operations. The system uses automated mechanisms to guide electric wires through routing paths, attach connectors to wire ends, and bundle wires according to the desired harness configuration, eliminating the need for manual operations while maintaining ease of use through simple programming or automated control
Solution Approach 2:
The apparatus replaces manual mechanical operations with automated mechanical systems. Robots or automated actuators perform wire routing, connector placement, and harness assembly tasks that would otherwise require manual dexterity and time, thereby dramatically increasing productivity while the system remains easy to operate through centralized control
Data Source
AI summary
A wire harness manufacturing apparatus 1 includes a plurality of connector cups 12 having a same outer shape as each other, a sub-harness mounting plate 13 on which a plurality of sub-harnesses W1a are mounted while the connector cup 12 is attached to the connector, a plate fixing portion 14, a plurality of slide portions 15 respectively holding one-end side connectors via the connector cups 12, base end holding portions 16 holding other-end side connectors via the connector cups 12, a connector transfer mechanism 17 detaching the one-end side connector and the other-end side connector together with the connector cup 12 from the sub-harness mounting plate 13 to the slide portions 15 and the base end holding portions 16, and an electric wire processing portion 18 performing electric wire processing on electric wires stretched between the slide portions 15 and the base end holding portions 16.