Method for making a wire harness

• US 4,803,778 A
• Filed: 08/19/1987
• Issued: 02/14/1989
• Est. Priority Date: 10/07/1983
• Status: Expired due to Fees

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Cross, Dan A.
• Primary Examiner(s): Weidenfeld, Gil
• Assistant Examiner(s): Howell, Daniel W.
• Application Number:
  US07/087,733
• Time in Patent Office: 545 Days
• Field of Search: 29/857, 29/861, 29/747, 29/748, 29/755, 29/33 M, 227/84, 226/126, 226/134, 226/149, 226/150, 226/151, 226/162
• US Class Current: 29/857
• CPC Class Codes: B25J 9/00 Programme-controlled manipulators
• CPC Class Codes: B65H 51/20 Devices for temporarily storing filamentary material during forwarding, e.g. for buffer storage
• CPC Class Codes: H01B 13/01245 using a layout board
• CPC Class Codes: H01R 43/28 for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
• CPC Class Codes: Y10T 29/49174 Assembling terminal to elongated conductor
• CPC Class Codes: Y10T 29/5193 Electrical connector or terminal
• CPC Class Codes: Y10T 29/53209 Terminal or connector
• CPC Class Codes: Y10T 29/53243 Multiple, independent conductors

Abstract

In the method of the present invention, a wire routing tool grasps a wire, inserts one end into a connector, routes the wire along a predetermined path to another end connector under the control of a robot, and inserts the second end into that connector. The trailing end of the wire is detected with a circuit using an electrostatic technique. The tool can move the wire along a predetermined linear path to effectuate the connection.

Claims

1. A method of routing a wire with a robot into a particular position in a wire harness assembly, wherein the wire harness assembly includes at least one connector having a plurality of pin-receiving points, comprising the steps of:

(a) cutting the wire to a predetermined length;

(b) terminating both ends of the wire length, at least one end being terminated with a pin;

(c) positioning the pin of the wire with a robot adjacent to the connector, including the substeps of;

(1) acquiring the terminated wire with a tool on the robot;

(2) moving the robot to position the tool adjacent to the connector;

(3) identifying a predetermined, pin-receiving point on the connector with the robot; and

(4) positioning the pin end of the wire with the robot in alignment with the predetermined pin-receiving point;

(d) inserting the pin of the wire with the robot into the first predetermined pin-receiving point on the connector, including the substeps of;

(1) securing a first point of the wire with a first foot of the tool;

(2) sliding a second foot of the tool to a second point of the wire removed from the first point;

(3) securely holding the wire at the second point with the second foot;

(4) moving the second foot from the second point to a point adjacent the first foot while allowing the wire to slide through the first foot to insert the wire into the connector;

(e) thereafter laying the wire with the robot into its particular position within the wire harness assembly; and

(f) releasing the wire from the robot.

2. The method of claim 1 further comprising, prior to releasing the wire, the steps of:

(a) positioning a second end of the wire with the robot adjacent to a second connector; and

(b) inserting the second end into the second connector with the robot.

3. The method of claim 1 further comprising the steps of repeating steps (a) through (f) for a second wire in the wire harness assembly, but connecting the second wire to a second, predetermined, pin-receiving point on the connector.

4. A method for making a wire harness assembly, comprising the steps of:

(a) positioning a plurality of connectors on a form board;

(b) positioning at least one turn gate on the form board;

(c) selecting a first wire for the harness;

(d) marking the wire;

(e) cutting the wire to a predetermined length;

(f) pin terminating the pre-cut wire at both ends;

(g) inserting a first pin end of the terminated wire into a first connector on the form board;

(h) routing the wire over the form board through the turn gate to a second connector; and

(i) inserting a second pin end of the terminated wire into the second connector, wherein each inserting step includes;

(1) securing a first point of the wire with a first foot of a robot;

(2) sliding a second foot of the robot to a second point of the wire removed from the first point;

(3) securely holding the wire at the second point with the second foot;

(4) moving the second foot from the second point to a point adjacent the first foot while allowing the wire to slide through the first foot to insert the wire into the connector.

5. The method of claim 4 further comprising the steps of:

(a) selecting a second wire;

(b) cutting the second wire to a predetermined length;

(c) marking the second wire;

(d) pin terminating the pre-cut, second wire;

(e) inserting a first pin end of the terminated, second wire into the first connector;

(f) routing the second wire over the form board through the turn gate to a third connector; and

(g) inserting a second pin end of the second wire into the third connector.

6. The method of claim 5 wherein the steps of pin terminating, inserting the first pin end, routing, and inserting the second pin end for both the first and second wires are done robotically.

7. A method for making a wire harness assembly using a robot, comprising the steps of:

(a) cutting a wire for the harness to a predetermined length;

(b) pin terminating both ends of the cut wire;

(c) acquiring the terminated wire with the robot;

(d) moving the wire adjacent a firt connector with the robot;

(e) identifying the location of a predetermined pin receiver on the first connector with the robot;

(f) inserting a first pin end of the wire into the pin receiver with the robot, including the substeps of;

(1) aligning the pin end with the pin receiver;

(2) clamping the wire with a first foot of the robot;

(3) moving a second foot of the robot to a position away from the first foot;

(4) clamping the wire with the second foot of the robot;

(5) unclamping the wire with the first foot; and

(6) moving the clamped second foot to a position adjacent the first foot while permitting the wire to slide through the first foot;

(g) routing the wire to a second connector;

(h) identifying the location of a predetermined pin receiver on the second connector with the robot;

(i) inserting a second pin end of the wire into the pin receiver of the second connector with the robot; and

(j) releasing the wire from the robot.

8. The method of claim 7 wherein the step of routing includes bending the wire at least once.

9. The method of claim 8 wherein the step of releasing the wire includes ejecting the wire from both feet of the robot.

10. The method of claim 9 wherein the step of acquiring the wire includes clipping the wire into a wire guide region fabricated into both feet of the robot.