Wire Harness Assembly Projection System for Dynamic Guidance
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Solution Overview
Problem
Conventional wire harness assembly equipment lacks the ability to dynamically update the assembly process images during the wire laying step, leading to potential errors in wire selection and placement, and the attachment of assembly jigs to incorrect positions, which can damage the equipment and reduce productivity due to worker variability.
Innovation Solution
A wire harness manufacturing equipment with a transparent screen for rear projection, a projector, and a remote controller that guides workers through the assembly process by displaying step-by-step images, ensuring accurate wire placement and jig attachment, and utilizing negative pressure or magnetic attachment to secure the assembly jig, reducing the risk of damage and improving ease of use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional drawing board device is used with static full-size drawing, then device complexity is reduced, but manufacturing precision deteriorates due to inability to dynamically update wire placement guidance
Solution Approach 1:
The patent uses projection to create a virtual copy of the wire harness assembly diagram on the screen, allowing dynamic display of wire paths and component positions without physical changes to the drawing board. This virtual copy can be updated remotely via the remote controller, maintaining manufacturing precision while avoiding complex mechanical reconfiguration systems.
Solution Approach 2:
The patent replaces the static mechanical drawing board system with an optical projection system. Instead of physically changing drawings or jigs when design changes occur, the system uses light projection to display updated assembly guidance, substituting mechanical reconfiguration with optical information delivery.
2Ease of operation
If assembly jig is attached by inserting through hole in wire laying board, then ease of operation is improved, but reliability deteriorates due to risk of damaging the board or jig
Solution Approach 1:
The patent extracts the attachment function from the wire laying board structure itself by using a separate projection screen that can be attached and removed independently. The screen serves as the interface for displaying assembly information without requiring structural modifications to the board, thus avoiding damage risks while maintaining ease of operation.
3Productivity
If multiple drawing board devices are used to manufacture multiple wire harnesses simultaneously, then productivity is improved, but manufacturing precision deteriorates due to variability in worker ability
Solution Approach 1:
The patent creates a universal assembly guidance system through projection that can be applied across multiple workstations. The same projected diagram and assembly instructions can be displayed on multiple screens simultaneously, ensuring consistent information delivery to all workers regardless of their individual abilities, thereby maintaining manufacturing precision while scaling productivity.
Solution Approach 2:
The system provides visual feedback through the projected images that guide workers through each assembly step. The remote controller allows for updating and standardizing the assembly instructions displayed, creating a feedback loop where correct assembly procedures are consistently communicated to all workers, reducing variability caused by different worker abilities.
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 solution reduces errors in wire selection and placement, ensures accurate jig attachment, and enhances productivity by allowing for real-time image updates during the assembly process, using a robust screen and secure attachment methods.
Implementation Method 1
a wire laying board to which various jigs required to assemble a wire harness can be attached, an assembly jig attached to the wire laying board to hold an electric wire to be laid, and a display means for displaying images of wire harness assembling process on the wire laying board so that the images can be seen on the front surface of the wire laying board
Implementation Method 2
in case that the assembly jig is configured to be attached to the wire laying board by being inserted through a hole formed on the wire laying board
Data Source
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AI summary
A wire harness manufacturing equipment comprises a plurality of display portions for displaying images, a memory unit that stores image data corresponding to an assembling process of a wire harness, a control means that controls the plurality of display portions so that the images displayed based on the image data stored in the memory unit are changed to follow the progress of the assembling process, and an acquiring means for acquiring progress information that indicates the progress status of the assembling process displayed on the plurality of display portions.