Automated Wiring Harness Production via Dynamic Rail Distribution

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Solution Overview

Problem

The manufacturing of wiring harnesses with branched structures in the automotive industry is complex and largely manual due to the diversity of variants, making automation challenging and time-consuming.

Innovation Solution

A system comprising a control unit, a distribution station with adjustable parallel rails and transporters that automatically spread and arrange conductor elements into a predefined branched structure, allowing for the complete automated manufacture of wiring harnesses without manual intervention, using a multi-axis jointed-arm robot for precise fitting and fixing of conductor elements and plug housings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If manual methods are used to lay and fix conductor elements according to predefined branched structures, then flexibility and adaptability to different wiring harness configurations are maintained, but productivity is low and manual labor is high

Engineering Contradiction:

Improveadaptability to different wiring harness configurationsVSAvoidproduction speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system employs dynamically adjustable parallel rails that can be repositioned along the transport direction to accommodate different branched structures of wiring harnesses. The rails and transporters are designed to be movable and reconfigurable, allowing the system to adapt to various conductor element arrangements while maintaining automated high-speed production

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The automated system is designed with universal components that can handle multiple wiring harness configurations. The parallel rail system and transporters can be adjusted to accommodate different branched structures, making the system versatile for producing various wiring harness types without requiring manual intervention for each configuration

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Productivity

If automated methods with fixed rail systems are used, then productivity and automation extent are improved, but adaptability to different branched structures is reduced

Engineering Contradiction:

Improveproduction speedVSAvoidadaptability to different branched structures

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

Inventive Principle:

Principle #15Dynamics

3Manufacturing precision

If conductor elements are laid along cable boards manually, then precision in positioning is maintained, but device complexity and manual labor increase

Engineering Contradiction:

Improvepositioning precision of conductor elementsVSAvoidcomplexity of manufacturing system

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system replaces manual mechanical laying operations with an automated transport system consisting of parallel rails and transporters. The automated positioning mechanism uses motorized rail adjustment and transporter movement to achieve precise conductor element placement, eliminating the need for manual cable board laying while maintaining positioning accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-service automated positioning where the parallel rails and transporters automatically adjust and position conductor elements according to the predefined branched structure. The control system coordinates rail movement and transporter positioning to achieve precise placement without manual intervention, reducing both manual labor and system operational complexity

Inventive Principle:

Principle #25Self-service

4Adaptability or versatility

If individual wiring harnesses are manufactured after customer orders are received, then adaptability to individual customer requirements is improved, but delivery time increases

Engineering Contradiction:

Improveindividual configuration capabilityVSAvoiddelivery time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system enables preliminary automated preparation of wiring harnesses by pre-configuring the parallel rails and transporters with conductor elements according to anticipated customer requirements. The automated assembly process can quickly reconfigure between different harness types, allowing near-real-time production response to individual customer orders while maintaining short delivery times

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS11550304B2System and method for the automated production of a wiring harness

Publication Date: 2023.01.10 LEONI BORDNETZ-SYSTEME GMBH & CO KG

AI summary

A system for the automated manufacture of a wiring harness, which demonstrates a branched structure made up of multiple individual conductor elements. To form wiring harnesses having an individually branched structure, the conductor elements are automatically brought into a predefined distribution structure, multiple second rails oriented in parallel to each other and multiple second transporters, distributed on the second rails, being used for this purpose. The second transporters are each fitted with one wire end of the conductor elements. To form the distribution structure, the second rails are subsequently moved in a vertical direction, and the second transporters are moved along the second rail. In this spread-apart structure, additional processing steps are carried out, for example a fixing of the conductor elements to each other.