Wire Harness Assembly Display System for Parallel Routing
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Solution Overview
Problem
Existing methods for manufacturing wire harnesses are inefficient, requiring sequential routing and assembly of bundles, leading to increased time, error risk, and learning curve, with modifications to 2D layouts necessitating reprinting and replacement of large paper sheets.
Innovation Solution
A method and system that generate and display bundle routes on a display surface using coordinates from a layout, allowing for parallel routing and assembly of wire harnesses by projecting images of bundle routes in a defined sequence, enabling workers to assemble harnesses more efficiently and reducing error risk.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If large paper sheets with 2D layouts are printed and placed on tables for manufacturing instructions, then workers have clear instructions about how to build the harness, but the process is time-consuming and requires reprinting when modifications occur
Solution Approach 1:
The patent replaces physical paper sheets with electronic display screens that show 2D layouts. The display device can be updated instantly by changing digital content without reprinting, while maintaining the visual clarity needed for manufacturing instructions. This resolves the contradiction by providing clear instructions through electronic copies that are easily modifiable.
Solution Approach 2:
The patent substitutes the mechanical process of printing and physically replacing paper sheets with an electronic display system. The display device receives digital signals and updates the shown layout electronically, eliminating the need for mechanical reprinting operations while maintaining instructional clarity.
2Productivity
If routing of bundles is completed before assembling terminals, then the assembly process follows a clear sequential order, but the process takes longer than if done in parallel
Solution Approach 1:
The patent divides the assembly process into distinct operational phases that can be independently managed and executed in parallel. The display device shows different portions of the layout (e.g., routing information, terminal assembly information) separately and sequentially, allowing workers to perform routing and terminal assembly simultaneously without confusion, thus improving productivity while managing complexity through structured segmentation.
Solution Approach 2:
The patent displays routing information and terminal assembly information in a predetermined sequence on the display device. By showing routing instructions first, then terminal assembly instructions, the system prepares workers in advance for each task phase, enabling smooth parallel execution of routing and assembly operations without increasing process management complexity.
3Loss of information
If workers manually trace and follow bundle routes on large paper sheets, then they can visualize the complete layout, but their traveling distance and assembly time increase
Solution Approach 1:
The patent creates a scaled electronic copy of the 2D layout on a display device that can be positioned close to the work area. Workers can view the complete layout visualization on the screen without needing to move around large paper sheets, significantly reducing travel distance while maintaining full visual information about bundle routes and terminal positions.
Solution Approach 2:
The patent transitions from a physical 2D paper sheet that requires physical movement to access different areas, to an electronic display that presents the same 2D information in a compact, stationary format. This dimensional transformation allows workers to view the entire layout from a fixed position, eliminating the need to travel across large distances while preserving complete visual information.
Data Source
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AI summary
The present document describes a method for assembling a wire harness on a display surface, the wire harness comprising bundles, each one of the bundles corresponding to a bundle route selected among possible bundle routes, each one of the possible bundle routes comprising two ends, the method comprising: receiving coordinates of a layout of the wire harness; generating at least a portion of all the possible bundle routes by identifying coordinates of the two ends of each one of the at least a portion of all the possible bundle routes from the coordinates of the layout of the wire harness; receiving wiring data which identifies the bundles to be used for the wire harness; determining which bundle routes among the possible bundle routes correspond to the bundles to be used; defining, from the coordinates of the two ends of the determined bundle routes, a sequence in which the bundles are to be routed to produce the wire harness; generating a plurality of signals, each one of the plurality of signals being representative of an image of the bundle route for a corresponding one of the bundles to be routed; and sending each one of the plurality of signals for display sequentially on the display surface according to the defined sequence.