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

摘要

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.

主权项

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