Wire Harness Assembly Using OCR-Guided Connector Insertion
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Solution Overview
Problem
The existing methods for manufacturing wire harnesses and cable assemblies are inefficient and prone to errors due to the complexity of the processes and the need for manual insertion of wires into connectors, which results in significant time and cost expenditures.
Innovation Solution
A computer-implemented system that automates the identification of wire markings and guides the error-free insertion of wires into connector pin-hole receptacles using a two-axis translation stage and light sources to illuminate the correct receptacles from below.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual methods are used for wire harness assembly, then flexibility and adaptability are maintained, but productivity is low and manufacturing precision is poor due to human error
Solution Approach 1:
The patent introduces an intermediary system consisting of a camera, computer vision algorithms, and control software that mediates between the human operator and the wire insertion process. The camera captures images of wire markings and connector pin-holes, the computer vision system processes these images to identify targets, and the control system guides the insertion process, thereby automating complex tasks while maintaining system flexibility
Solution Approach 2:
The patent replaces manual mechanical operations with automated vision-based identification and control systems. Instead of relying on human eyes to read wire markings and locate pin-holes, the system uses computer vision to automatically detect and identify these features, substituting mechanical human perception with automated optical and computational systems
2Manufacturing precision
If manual wire insertion is performed, then device complexity remains low, but manufacturing precision deteriorates due to mis-wiring and insertion errors
Solution Approach 1:
The patent implements a feedback mechanism where the camera continuously captures images of the connector and wire positions, the computer vision system analyzes these images to detect insertion status, and the system provides real-time feedback to guide corrections. This closed-loop feedback ensures high precision by immediately identifying and correcting insertion errors
Solution Approach 2:
The patent performs preliminary identification and verification of wire markings and pin-hole locations before actual insertion occurs. The vision system pre-locates all target positions and validates wire codes in advance, ensuring that insertion actions are based on pre-verified information, thereby preventing errors before they happen
3Productivity
If automated systems are introduced to increase productivity, then assembly speed improves, but device complexity increases significantly
Solution Approach 1:
The patent employs a universal vision-based platform that can handle multiple wire harness types, connector configurations, and wire marking styles through software configuration rather than hardware redesign. The same camera and computer vision system adapt to different assembly tasks by loading appropriate reference images and parameters, achieving multi-functionality without proportionally increasing hardware complexity
Solution Approach 2:
The patent uses optical copying through camera imaging to create digital representations of wire markings and connector features. Instead of requiring complex mechanical measurement systems, the system captures optical images and processes them computationally, replacing complex physical measurement apparatus with simpler optical copying and digital processing
4Loss of time
If traditional assembly methods are used, then equipment cost is low, but loss of time increases due to manual reading and verification processes
Solution Approach 1:
The patent substitutes manual reading and verification processes with automated computer vision systems. The camera captures images of wire markings and the software automatically reads and verifies code information, replacing slow and error-prone manual operations with fast automated optical recognition and digital processing
Solution Approach 2:
The patent enables continuous identification and verification of wire markings throughout the assembly process. Rather than intermittent manual checks, the vision system continuously captures and processes images of wire codes, maintaining constant verification and eliminating idle time between reading operations
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system significantly reduces the time and cost associated with wire harness assembly by minimizing human error and increasing efficiency, allowing for faster and more accurate assembly of complex wire harnesses.
Implementation Method 1
a wire marking reader...which detects colors and pattern markings on a wire covering
Implementation Method 2
light sources...which illuminate the pin-hole receptacles from below
Data Source
AI summary
The device, system and process of the present invention greatly reduces the time and space necessary to assemble a wire harness enables efficient manufacture of wire harnesses and cable assemblies. The present invention comprises at least a wire or cable viewer module, a machine vision and optical character recognition module, one or more receptacles designed to receive and hold in place a wire harness or cable assembly connector, having multiple pin-hole cavities illuminated by a light source to identify a cavity for wire or cable insertion. Moreover, the present invention may further comprise a portable, computer-implemented system capable of executing a series of automated process steps designed to identify wire and cable markings and guide the error-free insertion of identified wires and cables into wire harness connector pin-hole receptacles for assembly of a wire harness or cable assembly.