Bi-directional Wire Retaining Peg for Harness Assembly

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Solution Overview

Problem

Manual assembly of wire harnesses leads to inconsistent routing and potential damage due to slippage of wires on cylindrical pegs, and existing robotic solutions often require clamping that alters insulation or damages wires.

Innovation Solution

The use of pegs with a base, bi-directional wire receiving and retaining portions that restrict movement in multiple directions without altering the wire, allowing for automated placement on a wire harness peg board without manual tie-offs or clamps, utilizing a peg apparatus with pliable flaps and magnetic coupling for secure positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If manual assembly is used to place wires on cylindrical pegs, then flexibility and ease of operation are improved, but wire routing consistency and positioning precision deteriorate

Engineering Contradiction:

Improveease of wire placementVSAvoidwire routing consistency

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The peg is segmented into distinct functional zones: a receiving portion for initial wire placement and a retaining portion for securing the wire. This segmentation allows the wire placement process to be divided into discrete steps, improving both consistency and automation capability while maintaining operational simplicity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The peg acts as an intermediary device between the wire and the final harness assembly. Its specialized geometry with receiving and retaining portions mediates the wire placement process, ensuring consistent routing and positioning while enabling both manual and automated operation.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If robotic aids are used to place wires on cylindrical pegs, then productivity and automation are improved, but wire slippage and positioning reliability worsen

Engineering Contradiction:

Improveassembly speedVSAvoidwire retention stability

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The peg is divided into a receiving portion for initial wire placement and a retaining portion for securing the wire. This segmentation prevents wire slippage during automated robotic placement by providing distinct zones for wire engagement and retention, thereby improving both productivity and reliability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Instead of using cylindrical pegs that require external clamping forces to prevent slippage, the invention inverts the approach by designing a peg geometry where the retaining portion inherently secures the wire through its shape, eliminating the need for additional clamping mechanisms and improving wire retention stability during automated assembly.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If clamping pegs are used to prevent wire slippage, then wire retention reliability is improved, but wire integrity and insulation quality deteriorate

Engineering Contradiction:

Improvewire retention stabilityVSAvoidwire insulation damage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention inverts the traditional clamping approach by designing a peg with a retaining portion that secures the wire through its geometry rather than external clamping forces. This prevents damage to wire insulation and integrity while maintaining reliable wire retention.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The retaining portion of the peg features flexible, pliable flaps that conform to the wire and secure it through gentle contact rather than rigid clamping. This flexible approach prevents damage to wire insulation and integrity while maintaining reliable wire retention.

Inventive Principle:

Principle #30Flexible shells and thin films

4Device complexity

If automated placement without specialized pegs is used, then device complexity is reduced, but wire slippage and assembly reliability worsen

Engineering Contradiction:

Improvepeg structure simplicityVSAvoidautomated wire placement consistency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The peg is segmented into receiving and retaining portions, providing specialized functionality for automated wire placement. This segmentation ensures consistent wire positioning and retention during automation while maintaining relatively simple device complexity through integration into a single peg component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The peg serves multiple functions: initial wire reception, wire retention, and guidance during automated placement. This multi-functionality improves automated wire placement consistency while avoiding the need for multiple separate components, thereby managing device complexity effectively.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables consistent and secure automated placement of wires on a peg board, preventing slippage and damage, while maintaining wire integrity, thus improving the efficiency and reliability of wire harness assembly.

Implementation Method 1

utilizing a peg apparatus with pliable flaps and magnetic coupling for secure positioning

Methodology Applied

Scientific EffectMagnetic coupling: Magnetism

Data Source

PatentUS10411444B2Method of assembling electrical control panel wire harness

Publication Date: 2019.09.10 DESIGN READY CONTROLS

AI summary

A method is described that is suitable for automated use of peg apparatus and an electrical wire harness peg board. The pegs are utilized on a wire harness peg board during the assembly of a wire harness, and are particularly well suited for use in an automated assembly of the electrical wire harness where a constant upward, downward or lateral tension is desired without altering the free ends of each wire of a bundled wire harness.