Wire Harness Projection Guidance System
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional wire harness systems are labor-intensive and prone to errors due to the lack of guidance for routing wires, requiring skilled workers and resulting in high labor costs and imprecision, as each MCC unit has unique wiring requirements.
Innovation Solution
A wire harness projection guidance system that uses a projector to display images of wire routes onto a harness board, allowing non-skilled workers to construct precise wire harnesses by projecting pre-cut and pre-stripped wires with adjustable angles and color-coded indicia, reducing manual labor and errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manual wire routing methods are used, then operators can construct wire harnesses, but the process requires skilled workers, increases labor costs, and reduces productivity
Solution Approach 1:
The patent uses a projector to create a visual copy of the wire route schematic directly onto the harness board. This optical copy allows operators to see the exact wire paths without needing to interpret complex schematics, enabling non-skilled workers to perform the task efficiently while reducing labor costs and increasing productivity
Solution Approach 2:
The patent replaces the manual mechanical process of interpreting schematics and routing wires with an optical projection system. The projector displays wire routes visually, substituting the cognitive and manual effort required for schematic interpretation with a simple visual guidance mechanism, thereby reducing the skill level needed and increasing overall productivity
2Manufacturing precision
If standard harness boards are used without projection guidance, then the setup is simple, but wiring precision is poor and mistakes increase
Solution Approach 1:
The projector creates an accurate visual copy of the wire route schematic directly onto the harness board, allowing operators to see the exact wire paths. This visual copying mechanism ensures high wiring precision by displaying the precise routing information directly at the work location, eliminating the need for operators to interpret abstract schematics
Solution Approach 2:
The projection system acts as an intermediary between the wire route schematic and the harness board. It translates the schematic information into a visual display on the board itself, serving as a mediator that bridges the gap between design specifications and physical construction, thereby improving wiring accuracy
3Reliability
If operators work without visual guidance, then the process is simple, but the likelihood of wiring mistakes increases
Solution Approach 1:
The projector displays a visual copy of the wire route schematic directly on the harness board, providing continuous visual guidance to operators. This reduces wiring errors by allowing operators to verify their work against the projected image in real-time, eliminating the need to constantly reference separate schematic documents and reducing misinterpretation errors
Solution Approach 2:
The projection system provides visual feedback to operators during the wiring process. By displaying the correct wire routes directly on the work surface, the system allows operators to immediately verify their progress and correct mistakes, creating a feedback loop that reduces error rates and improves overall wiring reliability
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 enables efficient and precise wire harness construction with reduced labor costs and fewer errors, as it lays out wire routes accurately and consistently, even allowing non-skilled workers to assemble MCC units without understanding schematics.
Implementation Method 1
A projector is mounted to the support stand for projecting an image onto a wire harness board supported on the support stand
Implementation Method 2
a mirror may be mounted to the support stand and the projector projects the image to the mirror to be reflected onto a wire harness board supported on the support stand
Data Source
AI summary
A wire harness projection guidance system comprises a support stand for supporting a wire harness board used to construct a wire harness. A projector is mounted to the support stand for projecting an image onto a wire harness board supported on the support stand. A memory stores data representing wire route for each of a plurality of individual wires in a wire harness. A programmed processing system is operatively coupled to the memory and the projector for generating a series of images to be projected by the projector. Each image in the series represents one of the stored wire routes for an associated individual wire.