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Intelligent Status of Wiring Harness Assembly Processing
WINGUD 2023-01-05 15:33:21 5
Intelligent Status of Wiring Harness Assembly Processing
Considering the strong need for security and multimedia system improvement in the automotive industry, wire harness production is becoming increasingly important. Adapting to the integration of new technologies in vehicles is a challenge for wire harness manufacturers. At present, the production of wire harnesses is still very dependent on human resources, and the workload distribution method of the work station has a great effect on improving productivity. Components such as terminals, connectors, and seals are getting smaller, making manual handling more difficult. The solution to this problem may be to increase the degree of automation of wire harness production. In the automotive industry, a harness is a set of components (wires, terminals, connectors, seals, protection devices, fasteners, cable loops, fuses, relays, fuses and relay boxes, etc.) used to ensure connections between electrical and electronic components integrated into a vehicle. Harness diversity increases synchronically with the development of vehicles in terms of electrical and electronic functionality, integration of new communication technologies, control and software applications, becoming available options when purchasing a vehicle. This fact leads to an increase in complexity and therefore the weight of the wire harness in the weight of the vehicle. In the case of the Audi A8 (version 2018), for example, the harness weighs 36 kg and the wires that are part of the harness are put together to extend for several kilo meters. A version of the Mercedes-Benz OM654 engine harness provides a useful example to illustrate the complexity of the harness, which contains: 54 connectors, 116 wires, a length covering 4 m2 when straighten, and a weight of 1.5 kg.
Because of the increasing complexity, the automated wiring harness assembly process has the following difficulties: 1. It is difficult to handle because the wire as part of the wire harness is a very flexible element and has a long length; 2. Various components constituting the final harness: wires of different lengths and diameters, terminals, seals, connectors, protective devices, connectors, fasteners, etc. 3. Various operations required to ensure connectivity: simple crimping (manual or automatic), double wire crimping (manual or automatic), ultrasonic welding, twisting, penetration of terminal wire assemblies into connectors, application protection, etc. 4. The variety of wiring harnesses produced in a project, many references need different assembly boards (pallets); 5. Wiring structure changes occurred during the project development phase, involving rapid modification/adjustment of operation sequence and assembly system; 6. The changes brought about by aftermarket quality events, although smaller than in the development phase, also involve rapid adaptation of the wiring system. Harness automation, despite its progress, still requires manual manipulation and no technical solution for automation is available. Therefore, full automation will not be achieved overnight, and not all wire harness manufacturers can do it, but manufacturers who can improve the degree of automation will have advantages over other manufacturers and can produce higher quality and better cost products.
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