Wire Harness Routing on Form Boards Using Robotic Wire Group Handling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for assembling wire bundles in aerospace and automotive industries are inefficient, as they require manual routing of individual wires onto form boards, which is time-consuming and prone to errors.
Innovation Solution
A robotic system is introduced that routes groups of wires pre-assembled with ends inserted into connectors, using a manipulator arm and routing end effector controlled by a computer processor to automate the process, increasing efficiency and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual routing of individual wires is used, then flexibility in handling wire configurations is maintained, but assembly time and labor intensity increase significantly
Solution Approach 1:
The wire bundle is segmented into individual wires that can be independently routed, while the routing device itself is segmented into multiple form board devices that can be independently positioned and configured. This allows the system to handle complex wire configurations through modular components rather than requiring a monolithic complex device.
Solution Approach 2:
Form board devices serve as intermediary elements between the wire bundle and the final configuration. These intermediaries provide fixed positions and orientations that guide wire routing, enabling automated manipulation while maintaining flexibility in achieving various wire bundle configurations.
2Productivity
If pre-assembled wire groups are used, then assembly speed increases, but precision in positioning individual wires decreases
Solution Approach 1:
The wire group is segmented into individual wires during the routing process. The routing device manipulates the wire group as a unit for efficient transport, then segments it at the form board devices to achieve precise individual wire positioning. This dual approach enables both high-speed assembly and accurate positioning.
Solution Approach 2:
Different portions of the wire routing process have different quality requirements. The transport and initial positioning phases prioritize speed, while the final positioning at form board devices prioritizes precision. The system applies different levels of control and manipulation quality to different stages and locations in the routing process.
3Manufacturing precision
If customized form boards are created for each wire bundle configuration, then routing accuracy is improved, but device complexity and setup time increase
Solution Approach 1:
The routing device is designed with universal form board devices that can be used across multiple wire bundle configurations. Rather than creating customized form boards for each configuration, the same set of form board devices can be positioned and oriented differently to accommodate various routing requirements, reducing device complexity while maintaining routing accuracy.
Solution Approach 2:
The form board devices are positioned and oriented dynamically based on the specific wire bundle configuration requirements. Rather than being fixed in predetermined locations for each configuration, the devices can be moved and reconfigured, allowing a single set of devices to serve multiple purposes while maintaining precision for each specific routing task.
Data Source
AI summary
Methods and apparatus for automated routing of wires of a wire harness on a form board. A wire harness comprising a wire end connector and a multiplicity of groups of wires is supported and carried by a carrier end effector mounted to an end of a first robotic arm. The wire groups are accessed and then routed on the form board by a routing end effector mounted to an end of a second robotic arm. Initially a wire gripper of the routing end effector is opened. The second robotic arm is then controlled to move the routing end effector so that respective first portions of all wire groups are accessible for gripping by the wire gripper. Then the wire gripper is closed to grip the first portions of wires. Then the second robotic arm is controlled to move the routing end effector to place second portions of the wires of all wire groups in a first elastic retainer wire routing device attached to the form board. Thereafter, the routing end effector routes the first group of wires through a second elastic retainer wire routing device and then routes the second group of wires through a third elastic retainer wire routing device.