Patent Application
20190237927
This application claims the benefit under 35 U.S.C. § 119(a) of Patent Application No. 18154741.5 filed in the European Patent Office on Feb. 1, 2018, the entire disclosure of which is hereby incorporated by reference.
The present disclosure relates to an assisted method of electrically connecting a plurality of wires to a connector and to a corresponding assembly system. More specifically, the present disclosure relates to assembly methods and systems for electrically connecting the wires of a cable harness to a connector.
The present invention will now be described, by way of example with reference to the accompanying drawings, in which:
Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the various described embodiments. However, it will be apparent to one of ordinary skill in the art that the various described embodiments may be practiced without these specific details. In other instances, well-known methods, procedures, components, circuits, and networks have not been described in detail so as not to unnecessarily obscure aspects of the embodiments.
The present disclosure provides a method of electrically connecting a plurality of wires to connector that is based on robot or machine-assisted manual assembly. In the method of claim 1, a connector comprising a plurality of cavities is initially secured onto a base. A predetermined connecting sequence is loaded onto the memory of a guiding device that assists the assembly worker (hereinafter “user”).
Each step of the connecting sequence includes the location of one or more cavities of the connector that is configured to receive a wire, for example an end of a wire fitted with a terminal. For the sake of simplicity, the following disclosure refers to the ends of the wire, which also includes the terminals for connecting the wire to the housing. Next, a plurality of wires that each correspond to the respective steps of the connecting sequence are prepared. The connecting sequence is then started to automatically move the guiding device into place. This means that one or more channels defined by the guiding device are aligned with one or more cavities indicated in the first step of the connecting sequence such that the wire end can be guided through each channel and into the aligned cavity.
After the automatic aligning step, the user manually guides the end of the wire through the channel of the guiding device and into the aligned cavity to electrically connect or plug the wire. If the wire has multiple ends, each of the wire ends is guided through a corresponding channel and into an aligned cavity. In this way, the guiding device indicates the correct cavity for receiving a specific wire end to the user in a clear and simple manner. This reduces the likelihood that the wire end is plugged into the wrong cavity. Furthermore, the channel of the guiding device reduces the likelihood that the wire end or terminal is inserted at an angle that may cause the wire to bend or break. Once the wire has been plugged into the corresponding cavity, the wire is both electrically and mechanically connected to the connector, so the guiding device releases the wire to align the channel with the next cavity defined by the connecting sequence. The automatic aligning step, the manual guiding and connecting step and the automatic release step are repeated in this order until all of the steps of the connecting sequence have been executed.
The assisted assembly method of the present disclosure combines both manual and automatic assembly steps to improve output and quality while also maintaining the flexibility and lower assembly costs associated with a manual assembly process. Additionally, the method can be easily combined with existing methods to partially automate the cable harness assembly process, for example with systems and machines for automatically cutting wires and/or assembling terminals to the ends of wires.
Further embodiments and advantages of the assembly method are defined by the dependent claims and described in the following:
In some cases, the cable harness assembly process may incorporate cavity plugs for sealing cavities that are not configured to receive a wire end or terminal. Accordingly, an embodiment of the method may include the further steps of loading a predetermined plugging sequence on to the controller of the guiding device, with each step of the plugging sequence defining the location of one or more cavities that are not included in the connecting sequence. The plugging sequence is automatically started to move the guiding device to align the one or more channels with the one or respective cavities corresponding to the first step of the plugging sequence. The user then manually inserts a cavity plugs through the one or more channels and into the corresponding one or more cavities. The automatic aligning step and the manual plugging step are repeated until all of the steps of the plugging sequence of been executed. At this point, the connecting sequence can then be started. Using an assisted process for inserting cavity plugs eliminates the time necessary to correct the placement of cavity plugs before the wires can be plugged in or connected.
A further way of reducing process time is to manually guide both ends of a wire comprising a twisted pair through corresponding channels of the guiding device into the respective cavities at the same time. This embodiment is also advantageous over a fully automated assembly system, which may be unable to handle wires having more than one terminal attached to its end.
According to one embodiment, the releasing step can automatically occur once a specific amount of time has elapsed since the aligning step. This variation can stabilize the cycle times for assembly to reduce overall assembly time. However, the user may also need additional time to complete the manual guiding step, for example during training. In this case, the releasing step may optionally depend from a release signal provided to a controller of the guiding device, for example, by means of a button or a pedal.
The present disclosure also provides an assisted assembly system that comprises a base, which defines a base plane and is configured to support a connector, and a guiding device that includes first and second moveable gripping portions and an actuator for moving the gripping portions between an open and closed position, for example a servo drive or a pneumatic or hydraulic actuator. The gripping portions are configured to cooperate in the closed position to define one or more channels that extend perpendicularly to the base plane and are configured to receive one or more wire ends for manual insertion into connector cavities, while the actuator opens the gripping portions to release an inserted wire. The assembly system also comprises driving means for moving the base and/or the guiding device relative to each other, with the one or more channels remaining perpendicular to the base plane in order to automatically align the one or more channels with the respective connector cavities corresponding to the aforementioned sequence steps. Finally, the assembly system comprises a controller configured to control the driving means and the actuator of the gripping portions according to a predetermined sequence, for example the aforementioned connecting sequence and the optional plugging sequence.
The system of the present disclosure provides the necessary guidance and assistance for cable harness connector assembly, but is simple to implement. This reduces assembly error and improves quality over completely manual assembly systems without incurring the high start-up costs of fully automated assembly systems.
Further embodiments and advantages of the assisted assembly system are defined by the dependent claims and are described below.
In one embodiment, the driving means are configured to move the base within the base plane. For example, the base can be a motorized tray or board that provides movement within and perpendicular to the base plane, while the guiding device does not change its position relative to the base plane.
In another embodiment, the driving means may be configured to move the guiding device parallel and/or perpendicular to the base plane, for example, while the base remains stationary. Such arrangements may be perceived as more pleasant to use and provide ergonomic advantages. For example, a robot arm connected to the guiding device may form part of the driving means, as reasonably priced robot arms are available on the market. A robot arm can also be used to pivot the guiding device about an axis perpendicular to the base plane. This movement of the guiding device makes it possible to accommodate different orientations of terminals, in particular for twisted pair, jacketed or triple wires. In addition to a robot arm, other suitable means may be used to pivot the guiding device about an axis.
In addition to embodiments in which either the base or the guiding device are configured to remove while the other remains stationary, an embodiment in which the driving means are configured to move both the base and the guiding device relative to one another is conceivable. For example, the base may be configured to move within the base plane while the guiding device is configured to pivot about an axis that extends perpendicularly to the base plane.
In one embodiment, a contour of the one or more channels defined by the gripping portions may include a shape-matching feature that assists the user in the orientation of the wire end, particularly with a terminal attached to the wire end. For example, the channel may have the same contour as the outer contour of the connector cavity. Additionally or alternatively, the gripping portions may comprise opposing surfaces that are configured to abut one another when the gripping portions are closed, which defines one or more closed channels for guiding the end of a wire into a corresponding connector cavity. This feature is particularly advantageous in conjunction with the shape-matched contour of the channel. However, even if there is a minor gap between the opposing surfaces of the gripping portions, the guiding device is still able to assist the user in assembling the connector.
In another embodiment, the guiding device may include mounting means for mounting the guiding device. The mounting means make it possible to produce a custom-made gripping device and attach it to readily available driving means, such as a robot arm. This embodiment may include any suitable known mounting means, for example a screwed connection, but it may particularly include mounting means that can be operated without tools, such as a shape-matched or snap-fit connection. Mounting means that can be operated without tools make it possible for the user to switch out different guiding devices while keeping the same driving means to provide a simple and relatively inexpensive modular assembly system. Switching out different guiding devices may be made easier if the first and second gripping portions are connected to one another to form a single removable unit. For example, the gripping portions may include a spring-loaded or biased connection that biases the gripping portions in their closed position, and the actuator acts against the biasing force to open the gripping portions and automatically release the inserted wire(s).
In one embodiment, the guiding device may include a removable attachment portion that defines one or more apertures that extend in parallel to the channels defined by the gripping portions. Preferably, this attachment portion can be attached to the guiding device without the use of tools, such as by shape-matched or snap-fit connection. The attachment portion may be convenient for plugging cavity plugs into some of the connector cavities before the wires are inserted through the channel(s) of the gripping portions.
In another embodiment, the gripping portions may be asymmetric about a plane extending perpendicularly to the base plane. Such an asymmetry may be used to form an outer contour of the channel(s) that is shape-matched to the cavity contour or the outer contour of the terminals. However, the asymmetry of the gripping portions may also include one outer edge of the gripping portion that extends in parallel to said plane while the other outer edge is arranged at an angle. The angled outer edge may form a trailing edge that accommodates previously inserted wires as the guiding device moves from one cavity to the next. In any case, the gripping portions may also be symmetric about the aforementioned plane, i.e. formed in mirror image. Such symmetric gripping portions may be simple to manufacture.
In yet a further embodiment, the system may comprise an input device, e.g. a button or a foot pedal, for sending a release signal to the controller to release an inserted wire from the channel of the guiding device. This embodiment allows the user to determine the speed of the connecting sequence, e.g. during training.
The system 20 also includes a guiding device 24 that is arranged vertically above the connector 10 and includes a channel 26 that is aligned with one of the cavities 14 of the connector 10, as indicated by the dashed line in
In
After opening to release the first wire 16 (see
The channel 26 is then aligned with a further cavity 14 so that a subsequent wire 16 can be inserted into the cavity 14 (see
The cross-section in
The partial cross section of
The cross-sectional view of
While the previous disclosure describes an assisted system 20 and assembly method in the specific context of cable harnesses, the disclosure is not limited to such applications and may also prove advantageous in other applications that require the electrical connection of wires or cables to a connector or connector housing.
While this invention has been described in terms of the preferred embodiments thereof, it is not intended to be so limited, but rather only to the extent set forth in the claims that follow. For example, the above-described embodiments (and/or aspects thereof) may be used in combination with each other. In addition, many modifications may be made to configure a particular situation or material to the teachings of the invention without departing from its scope. Dimensions, types of materials, orientations of the various components, and the number and positions of the various components described herein are intended to define parameters of certain embodiments, and are by no means limiting and are merely prototypical embodiments.
Many other embodiments and modifications within the spirit and scope of the claims will be apparent to those of skill in the art upon reviewing the above description. The scope of the invention should, therefore, be determined with reference to the following claims, along with the full scope of equivalents to which such claims are entitled.
As used herein, ‘one or more’ includes a function being performed by one element, a function being performed by more than one element, e.g., in a distributed fashion, several functions being performed by one element, several functions being performed by several elements, or any combination of the above.
It will also be understood that, although the terms first, second, etc. are, in some instances, used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first contact could be termed a second contact, and, similarly, a second contact could be termed a first contact, without departing from the scope of the various described embodiments. The first contact and the second contact are both contacts, but they are not the same contact.
The terminology used in the description of the various described embodiments herein is for the purpose of describing particular embodiments only and is not intended to be limiting. As used in the description of the various described embodiments and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
As used herein, the term “if” is, optionally, construed to mean “when” or “upon” or “in response to determining” or “in response to detecting,” depending on the context. Similarly, the phrase “if it is determined” or “if [a stated condition or event] is detected” is, optionally, construed to mean “upon determining” or “in response to determining” or “upon detecting [the stated condition or event]” or “in response to detecting [the stated condition or event],” depending on the context.
Additionally, while terms of ordinance or orientation may be used herein these elements should not be limited by these terms. All terms of ordinance or orientation, unless stated otherwise, are used for purposes distinguishing one element from another, and do not denote any particular order, order of operations, direction or orientation unless stated otherwise.
| Number | Date | Country | Kind |
|---|---|---|---|
| 18154741.5 | Feb 2018 | EP | regional |
