Wire Harness Assembly With OCR-Guided Connector Pin Insertion
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Solution Overview
Problem
Conventional methods for manufacturing wire harnesses and cable assemblies are labor-intensive, prone to mis-wiring errors, and require significant time and cost due to the complexity of inserting wires into small, densely packed connectors, especially with thinner wires and dense connectors like Amphenol 2M805, leading to inefficiencies and high rework costs.
Innovation Solution
A computer-implemented system with a wire marking reader, cassette tray, two-axis translation stage, and light sources that automate the identification and error-free insertion of wires into connector pin-hole receptacles, using OCR for wire marking recognition and illuminating pin-hole receptacles from below to guide insertion, reducing human intervention and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional hand-assembly methods are used for wire harness manufacturing, then flexibility and adaptability are maintained, but manufacturing precision and productivity deteriorate due to the complexity of inserting wires into densely packed connectors
Solution Approach 1:
The patent introduces an intermediary illumination system with light sources positioned beneath the connector assembly. This intermediary device (lighting system) mediates between the assembler and the pin-hole cavities, projecting light upward to clearly indicate which cavities require wire insertion. This resolves the technical contradiction by providing precise guidance without requiring complex automated insertion mechanisms.
Solution Approach 2:
The patent replaces complex mechanical positioning and identification systems with a simpler optical illumination system. Instead of using complex mechanical guides or automated positioning devices, the invention uses light projection to indicate target pin-hole cavities, thereby improving manufacturing precision while reducing device complexity.
2Productivity
If conventional hand-assembly methods are used for wire harness manufacturing, then equipment cost is reduced, but productivity and assembly time deteriorate due to the time-consuming nature of manual wire insertion
Solution Approach 1:
The patent implements preliminary action by pre-positioning light sources beneath the connector assembly and pre-programming the illumination sequence to correspond with the wire insertion sequence. This preliminary setup eliminates the need for complex real-time calculation and decision-making during assembly, thereby improving productivity while keeping equipment costs low.
Solution Approach 2:
The illumination system is designed to be self-regulating, automatically indicating the next pin-hole cavity that requires wire insertion based on the predefined sequence. The system serves itself by providing continuous guidance without requiring external intervention or complex control mechanisms, thus improving assembly speed without increasing equipment complexity.
3Manufacturing precision
If conventional hand-assembly methods are used for wire harness manufacturing, then equipment simplicity is maintained, but manufacturing precision deteriorates due to the difficulty of identifying correct pin-hole cavities
Solution Approach 1:
The patent applies local quality by providing targeted illumination to specific pin-hole cavities rather than uniformly lighting the entire assembly area. Each light source is positioned to illuminate only the specific cavity that requires wire insertion at that moment, thereby improving identification accuracy without requiring a complex overall lighting system.
Solution Approach 2:
The patent introduces a new dimension of illumination by positioning light sources beneath the connector assembly and projecting light upward through the pin-hole cavities. This dimensional change allows assemblers to clearly identify target cavities from the top view, improving manufacturing precision without adding complex lateral positioning systems.
4Reliability
If conventional hand-assembly methods are used for wire harness manufacturing, then equipment cost is reduced, but reliability deteriorates due to the high rate of mis-wiring errors
Solution Approach 1:
The patent implements feedback by providing real-time visual indication through the illumination system, which continuously guides the assembler to the correct pin-hole cavity. This feedback mechanism ensures that wires are inserted into the correct locations, thereby improving reliability without requiring complex verification or correction systems.
Solution Approach 2:
The patent utilizes color changes in the illumination system to indicate different states or types of pin-hole cavities. By using different colors to represent different insertion requirements or cavity types, the system improves wire insertion accuracy while maintaining relative simplicity in the guidance mechanism.
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 assembly time and errors, achieving 90% accuracy in wire insertion within seconds, minimizing rework and costs, and ensuring efficient assembly even in confined spaces.
Implementation Method 1
using OCR for wire marking recognition
Implementation Method 2
illuminating pin-hole receptacles from below to guide insertion
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.