Integrated wire harness batch production with double buffer assembly systems and methods

• US 9,257,808 B1
• Filed: 05/02/2012
• Issued: 02/09/2016
• Est. Priority Date: 09/10/2010
• Status: Active Grant

• Current Assignee: Automated Wiring Systems, LLC
• Original Assignee: Automated Wiring Systems, LLC
• Inventors: Guglielmo, Kennon, Peterson, Eric
• Primary Examiner(s): Vo, Peter DungBa
• Assistant Examiner(s): Kue, Kaying
• Application Number:
  US13/462,572
• Time in Patent Office: 1,378 Days
• Field of Search: 295/93, 295/641, 29/33.M, 29729-742, 29745-754, 700/97, 414/331.08
• US Class Current: 1/1
• CPC Class Codes: G06F 2113/16 Cables, cable trees or wire harnesses
• CPC Class Codes: G06F 30/00 Computer-aided design [CAD]
• CPC Class Codes: H01B 13/012 for manufacturing wire harnesses
• CPC Class Codes: H01B 13/01209 Details
• CPC Class Codes: H01B 13/01218 the wires being disposed by hand
• CPC Class Codes: H01B 13/01245 using a layout board
• CPC Class Codes: H01R 43/033 for wrapping or unwrapping wire connections
• CPC Class Codes: H01R 43/04 for forming connections by deformation, e.g. crimping tool
• CPC Class Codes: H01R 43/05 with wire-insulation stripping
• CPC Class Codes: H01R 43/052 with wire-feeding mechanism
• CPC Class Codes: H01R 43/20 for assembling or disassembling contact members with insulating base, case or sleeve
• 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 29/5193 Electrical connector or terminal
• CPC Class Codes: Y10T 29/53243 Multiple, independent conductors

Abstract

Automated wire harness production systems and methods that rapidly present individual circuits to an assembler operating a wire harness layout board. Automatic wire indexing, sorting, and delivery systems transfer circuits into, and retrieve circuits from, a transportable programmable, automated, indexed storage system equipped with an array of individual circuit tubes, and a script-controlled assembly system sends visual, aural, and other cues to help an assembler populate and configure a wire harness layout board with connector blocks and turn posts, and guides the assembler in building, testing, reworking, and delivering the corresponding batch of wire harnesses.

Claims

1. A computer controlled wire harness assembly system comprising:

a. an automated wire cutting and prepping machine that is programmable to produce circuit elements having predetermined lengths;

b. a circuit storage and transport structure comprising

i. an array of tubes mounted to a movable frame, wherein each one of the tubes is able to receive one (or more) of the circuit elements produced by said automated wire cutting and prepping machine;

c. a computer-controlled circuit indexing, sorting, and transport system comprising;

i. a first conduit for directing transfer of the circuit elements from said automated wire cutting and prepping machine to said circuit storage and transport structure; and

ii. a memory for remembering the corresponding locations of the circuit elements in the circuit storage and transport structure;

d. a computer-controlled circuit retrieval system for conveying the circuit elements from their corresponding remembered locations in said circuit storage and transport structure, said computer-controlled circuit retrieval system comprising;

i. a presentation system for presenting the conveyed circuit elements for assembly; and

ii. a second conduit for directing conveyance of the circuit elements from the remembered locations in said circuit storage and transport system to said presentation system;

e. said presentation system comprising;

i. a circuit element buffer surface having a length that is long enough to receive the predetermined length of a circuit element conveyed from said circuit storage and transport system, wherein said circuit element buffer surface is positioned to receive the conveyed circuit element from said second conduit and to temporarily support the conveyed circuit element that is received from the second conduit;

ii. a circuit element tray that has a length long enough to receive the predetermined lengths of circuit elements retrieved from said circuit storage and transport system, said circuit element tray defining a space that is accessible to an assembler;

iii. an air knife for laterally moving the received circuit element from said circuit element buffer surface to the accessible space of said circuit element tray; and

iv. a circuit element sensor for detecting the presence or absence of the circuit element in the accessible space of said circuit element tray.

2. The computer controlled wire harness assembly system of claim 1, wherein said tray is positioned parallel and laterally adjacent to said buffer surface.

3. The computer controlled wire harness assembly system of claim 1, wherein said presentation system comprises a cover positionable over said buffer surface, said cover restricting access to circuit elements positioned on said buffer surface, and further comprising a wire harness assembly subsystem for assembling presented circuit elements into a wire harness, said presented circuit elements being sequentially retrieved for assembly from the accessible space of said circuit element tray.

4. The computer controlled wire harness assembly system of claim 3, wherein said wire harness assembly subsystem comprises:

f. a layout board;

g. an assembly table programmable module for said layout board;

h. a communication means for communicating assembly instructions for the wire harness to said assembly table programmable module; and

i. one or more displays for displaying graphic images to assist in the assembly and testing of wire harnesses assembled on said layout board.

5. The computer controlled wire harness assembly system of claim 4, wherein said displays comprise a projector control subsystem and a projector for assisting in the assembly of the wire harness.

6. The computer controlled wire harness assembly system of claim 1, wherein the circuit elements comprise individual wire segments with terminal ends.

7. The computer controlled wire harness assembly system of claim 1, wherein said automated wire cutting and prepping machine comprises manual mechanisms for wire cutting, stripping, crimping, and labeling.

8. The computer controlled wire harness assembly system of claim 1, wherein the first conduit comprises a first pneumatic tube and the second conduit comprises a second pneumatic tube.

9. The computer controlled wire harness assembly system of claim 1, wherein the second conduit comprises one or more conveyor belts.

10. The computer controlled wire harness assembly system of claim 1, wherein the tubes of the circuit storage and transport system are plastic.

11. The computer controlled wire harness assembly system of claim 1, wherein the computer-controlled circuit indexing, sorting, and transport system and the computer-controlled circuit retrieval system are one in the same.

12. The computer controlled wire harness assembly system of claim 1, wherein the circuit storage and transport structure is transportable.

13. The computer controlled wire harness assembly system of claim 1, wherein said automated wire cutting and prepping machine comprises an automatic programmable mechanism capable of wire cutting, stripping, crimping and labeling to produces circuit elements.

14. The computer controlled wire harness assembly system of claim 1, wherein said automated wire cutting and prepping machine is programmable by operator command.

15. The computer controlled wire harness assembly system of claim 1, wherein said automated wire cutting and prepping machine is programmable from a remote data input terminal device.

16. The computer controlled wire harness assembly system of claim 1, wherein said automated wire cutting and prepping machine is programmable by importing files from CAD software.

17. The computer controlled wire harness assembly system of claim 1, further comprising

a. a first optical sensor associated with said first conduit to enable detection of a circuit element entering into said first conduit;

and

b. a second optical sensor associated with said first conduit to enable detection of a circuit element passing out of said first conduit.

18. The computer controlled wire harness assembly system of claim 1, wherein each of said tubes of the circuit storage and transport structure is of identical length and diameter.

19. The computer controlled wire harness assembly system of claim 1, wherein each of said tubes of the circuit storage and transport structure has a length of at least 10 feet.

20. The computer controlled wire harness assembly system of claim 1, wherein each of said tubes of the circuit storage and transport structure have a diameter between 5/8 and 9/16 of an inch.