Wire Harness Inspection Using Step-Switched Connector Verification
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Solution Overview
Problem
Conventional wire harness assembly drawing apparatuses do not automatically switch images based on operation steps, leading to potential mistakes in wiring and connector connection, and require manual inspection, which is time-consuming and unreliable.
Innovation Solution
A method utilizing a wire harness production apparatus with a screen, mirrors, a projector, barcode reader, and electronic pen system that projects and manages assembly steps, reads barcodes, and provides visual feedback to ensure accurate assembly and inspection, reducing human error and inspection time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection is performed using operation instruction documents, then inspection can be conducted, but inspection time is long and reliability is low
Solution Approach 1:
The system provides real-time visual feedback through projected images that automatically switch based on operation steps. The projected images show checkmarks, crosses, or highlights to immediately indicate whether wiring or connector connections are correct, eliminating the need for manual document checking and providing instant verification feedback to operators.
Solution Approach 2:
The patent replaces manual inspection using paper documents with an automated optical projection system. The projector displays visual guidance and inspection results on a screen, substituting the mechanical process of manually reading and checking documents with an automated visual display system that provides real-time feedback.
2Manufacturing precision
If conventional assembly drawing apparatus is used, then assembly guidance is provided, but images are not switched automatically causing wiring mistakes
Solution Approach 1:
The system dynamically switches projected images based on the current operation step. As operators progress through wiring steps, the projection automatically updates to show the next required action, connector positions, or inspection criteria, making the system adaptive to the current state of assembly rather than static.
Solution Approach 2:
The system provides real-time visual feedback through projected images that automatically switch based on operation steps. The projected images show checkmarks, crosses, or highlights to immediately indicate whether wiring or connector connections are correct, eliminating the need for manual document checking and providing instant verification feedback to operators.
3Reliability
If projected images do not include connector images, then projection is simple, but connector connection mistakes occur
Solution Approach 1:
The projection system divides the assembly process into distinct segments or steps. Each projected image corresponds to a specific operation step, showing only the relevant information needed for that step (such as connector positions, wiring routes, or inspection points). This segmented approach provides comprehensive guidance without overwhelming the operator with all information at once.
Data Source
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AI summary
A method of inspecting a wire harness, includes steps of: switching an image corresponding to an assembly step of the wire harness in accordance with an advancement of the assembly step to display the image on a display unit; reading connector identification information attached to a connector to be connected to an electric cable configuring the wire harness and connector identification information displayed on a connector image included in the image; determining whether or not the read connector identification information attached to the connector and the read connector identification information displayed on the connector image match each other; making a correspondence between a determination result and identification information about an assembly product of the wire harness, and accepting the determination result as operation history information for each assembly step; and inspecting the assembly product of the wire harness on the basis of the operation history information for each assembly step.