JPS61173412A - Flexible automatic production apparatus for wire harness - Google Patents

Abstract

(57) [Abstract] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an automatic manufacturing apparatus and apparatus for manufacturing cable harness assemblies such as those utilized for interconnecting electrical subsystems in large scale electrical systems such as radar systems. Related to manufacturing method.

In modern radar and electro-optical systems, many of the subsystems are designed as modules to facilitate testing, maintenance, and component replacement. These module subsystems must be interconnected electrically, often through the use of cable harnesses. Radar system manufacturers may manufacture several types of radar systems and various other electrical devices at the same time. Therefore, it is necessary to manufacture a variety of cable harnesses. These cable harnesses vary in wire thickness, length, terminal type, and wiring route.

Traditionally, it has been the practice to utilize wire cedar boards configured to allow manual wire laying to lay out the cable harness according to the intended assembly path. This manual installation is time consuming and requires repeated checks to ensure accuracy in wire selection and installation route.

In order to be able to manufacture this type of cable harness accurately and at low cost, it is desirable to have automated wire processing equipment and cable harness assembly equipment.

Cable harness manufacturing and design data are input,
One example is an automated device that utilizes this data to control automated machining of pieces of wire of a predetermined diameter and length.

These wire pieces are formed with predetermined terminal means at each end. Wire selection, cutting, and terminal formation are performed by wire processing equipment operated under the control of computer means, such as a general purpose digital computer or dedicated microprocessor means.

The terminal wire is automatically fed from the wire processing equipment to the cable harness forming equipment by a conventional robot having a suitable end effector for gripping the end. The cable harness forming apparatus is operated under the control of computer means into which manufacturing and design data relating to the intended cable harness are input. This computer means may be the same as for the wire processing equipment or may be different. Manufacturing and design databases are used for both wire processing equipment and cable harness forming equipment. A cable harness former is also a robotic system having a suitable end effector for sequentially laying individual wires along a planar profile.

The shape plate includes anchoring pieces arranged in a predetermined pattern and upstanding from a flat surface of the shape plate. The robot end effector grasps the first end of the wire with a terminal and lays the wire in a predetermined pattern along the cedar board while mooring it to the mooring piece that defines the wire route, and lays all the wires that make up the cable harness. The wires are laid sequentially along the entire length of the cable until it is tied together with cable ties.

Such cable harnesses, which bundle several individual wires with various terminals into cables and often have several branch wires branching off from the main wire, can be removed from the cable harness former and pre-positioned. It can be used immediately to interconnect electronic components or subsystems that are currently being used.

Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

In the automated apparatus for forming cable harness assemblies schematically illustrated in FIG. 1, cable harness design data are manually entered via line 10 to computer means 12. Cable harness data typically takes the form provided by, for example, CAD equipment used to design the vast numbers of specialized cable harnesses required by radar system manufacturers. The automation device of the present invention provides extremely flexible manufacturing capabilities in view of the large variety of cable harnesses that must be manufactured for use with a variety of electronic subsystems, such as those used in radar systems. is configured to provide.

The computer means 12 may be a general purpose digital computer or microprocessor means with suitable software and memory. Computer means 12 is input with cable harness data and outputs control signals which are supplied via line 14 to automatic wire processing equipment 16. The functions of the wire processing device 16 are to receive the wire supplied along the line 18 from a wire storage means (not shown); cut it into a desired length; form a required terminal means on the end of the wire; The purpose is to mark the wire with identification information that allows it to be visually checked and recorded. In wire processing equipment, the wire supply and storage means are actually integrated with the wire processing equipment, but in order to make it easier to understand the automatic cable harness manufacturing equipment in a broader sense, the wire supply and storage means are deliberately illustrated as separate elements. did.

The terminal wires produced successively by the wire processing device 16 are fed along a line 20 to a conveying means 28, from where they are conveyed along a line 30 to a cable harness forming device 22. Cable 2 wires with terminals
In its simplest form, the conveying means 28 for feeding the harness forming device 22 may be manually operated by an operator;
In many cases, it is an automated robotic device having a suitable end effector for gripping the terminal wire; removing the kinks from the wire processing device 16 and conveying them to the cable harness forming device 22.

The cable harness former 22 sequentially lays individual terminal wires along a predetermined cable path in accordance with control signals sent from the computer means 12 via a line 24 to the cable harness former 22.

Cable harness forming apparatus 22 includes robotic means having a suitable end effector for guiding the cable according to a predetermined path defined by cable harness design data input and stored in computer means 12. Lay the wire on the cedar board to be assembled while moving in rectangular coordinates. The wires are bundled into a cable by suitable convergence means and the terminal wires are laid one after another until the cable harness is completed. Such cable harnesses can span several feet;
It typically includes a plurality of branch paths branching off from the main path, which may be configured to precisely match the interconnections of the electronic subsystems under the expected environment of the cable. The subsystem is easy to test;
LR is also used in the latest aircraft radar and equipment.
A replaceable modular electronic unit such as U (line replaceable unit) can be considered.

The completed cable harness is removed from cable harness forming device 22 along line 26. At this point, the flexible automatic cable harness manufacturing device of the present invention utilizes the same cable harness design data to
Another cable harness can be manufactured exactly as previously manufactured, or a different cable harness can be formed based on different cable harness design data. That is, the apparatus of the present invention is capable of producing each of the numerous types of unique cable harnesses required by manufacturers of modern electronic equipment.

To begin assembly, a conventional robot with a given end effector must first capture the wire and grip it in preparation for insertion. As already mentioned, wires with terminals are formed in wire processing equipment that cuts the wire to a predetermined length; trims both ends of the wire; and provides a suitable connector at each end of the wire and secures it by crimping or soldering. be done. The suitably terminated wire is conveyed by automated equipment or by hand for delivery to the desired end effector.

An example of an automated device for passing terminal wires to an end effector is a pneumatic wire transfer device. Generally, a pneumatic wire transport device includes a wire supply means and an air supply source. A pneumatic feed tube extends from the wire feed means to the end effector end insertion point. The fabricated wire is fed to the feeding means and then pneumatically driven to convey it through the tube to a position where a predetermined end effector can engage one end of the terminal wire.

Practical cable harness assembly equipment utilizes industrial manipulators to position and guide the end effector along a predetermined cable harness path. 1
As an example, a gantry type orthogonal axis manipulator device is illustrated in FIG. This type of robot is particularly useful because it can be programmed according to Cartesian coordinates. cable·
The harness assembly cedar board 131 is placed within the working range of the manipulator. The manipulator device 181 consists of three orthogonal axis assemblies: an X gold assembly 183, a Y gold assembly 185, and a Z gold assembly 187. General-purpose robot hand H
For mounting, a selective multi-axis rotating wrist mechanism 189 is fixed to the Z gold assembly 187.

The general purpose robot hand H includes a finger means F for engaging and manipulating any one of a plurality of individual end effectors. Due to the complexity of cable harness formation and the variety of connectors included in a given cable harness, it is preferable to utilize several dedicated end effectors 191. One example of an end effector dedicated to cable harness assembly is a bidirectional connector pin insertion tool.

The combination consisting of the X, Y% and Z-axis collection assembly is supported in a gantry-like manner by a vertical support member SM fixed to the factory floor. The manipulator device 181 is operated like a machine tool by a known numerical control console, such as the PRODUCERCNC system available from Westinghouse Electric Co., Ltd., Simin. This complete gantry orthogonal axis manipulator system significantly reduces the number of wrist joints required to perform the required cable harness assembly and eliminates the need for auxiliary equipment such as rotary tables traditionally required for cedar plank installation. It also reduces

The cedar board 131 is formed for a cable harness in which a plurality of branch lines B1 to B5 are branched from a wooden line T. This is a relatively simple cable harness and is shown as an example for illustrative purposes only. Given the complexity of electronic systems and the fact that the modular components that make up a given electronic device are physically separated from each other, the length of the individual branches, the number of branches and connectors as terminals on each branch is specific to the system using this cable harness. The cedar board 131 also includes a plurality of assembly points A1-A5 and mooring members or wire laying bins. The specific arrangement of the wires in the cable harness is a manufacturing requirement and is determined by the intended use of the cable harness itself. Accordingly, any number of different types of tethers and connectors may be used in the apparatus and method of the present invention.

As can be seen from the enlarged view of assembly points A3, A4 and A5, there are any number of different wire terminals in a given cable harness. For example, the enlarged view of assembly point A3 is a standard military connector into which wires with multiple pin connector terminals can be inserted. The enlarged view of assembly point A4 shows a known lug-type connector, and the enlarged view of assembly point A5 shows a simple tin-plated bare wire processed for later assembly.

To provide an overview of the cable harness forming process, the individual stages of the manufacturing process will be briefly described. First, the hand H of the gantry robot 181 engages a predetermined end effector that matches the type of wire to be inserted. When the corresponding end effector is captured, the wire conveying device passes the terminal-equipped wire to the end effector. A terminal wire is then inserted into the end effector. The terminal wire is aligned as desired within the end effector, and the end effector is then positioned so that the first end of the terminal wire is proximate the first intended assembly point.

a first end of the terminal wire is inserted into the first assembly point;
Laying of wires with terminals along the predetermined cable harness layout begins. As will be explained in detail later, the end effector is used for both wire laying and wire insertion, but it is practical to use one gripper for inserting wires with terminals and another gripper for laying them. It is. When using separate grippers for each task, the dedicated gripper 191 is selectively utilized by the robot hand H. The robot then follows a predetermined path to lay the wire along the tether to a second assembly point. Depending on the cable harness configuration, the second
The assembly points become the final position of the wire on the cedar board, as in the case of assembly points A4 and A5, for example. The above steps are repeated until the cable harness is completed. When the assembly of the cable harness is completed, the cable harness is removed from the cedar board 131, and by attaching the necessary mooring pieces and connectors, the cedar board can be used for the next cable harness formation. .

Having thus outlined a method and apparatus for manufacturing high density cable harnesses, by way of example, specific end effectors that utilize multiple plug connectors to assemble complex cable harnesses are described below. In the light of experience, it is preferred to use an orthogonal axis manipulator device, such as the UNIMATE Series 60QQ electric robot described above, for such assembly. A dedicated end effector is shown in an exploded perspective view in FIG. 2 along with a portion of the gripper shown in FIG.

The blank end effector 11 is comprised of a pair of mounting brackets 13.15, an assembly tool 17, and a wire tension/socket opening 19. For installation, the bracket 13.15 connects the end effector 11 to the robot.
Hole 21 is used for removably attaching to the hand.
Bayonet mount used with robot hand,
or the attachment mechanism is unique to the particular host robot to which the gripper or end effector is attached. As schematically shown in FIG.
It has a pair of fingers. This finger can grip the mounting bracket 13.15. Such attachment employs a mechanism so that as the fingers F move toward or away from each other, the outer gripper jaws attached to the brackets 13.15 also move toward or away from each other. In mounting, the bracket 13 is a generally L-shaped member from which a cantilever arm 23 projects. The cantilever arm 23 to which the movable wire pulling/6-erecting tool 19 is attached may be formed integrally with the bracket 13, or may be fixed to the bracket 13 as a separate member.

Attachment brackets 13,15 each support an assembly tool 17. The assembly tool 17 consists of two symmetrical parts or halves 25.27 which cooperate like jaws to grip the wire and place it in the connector or assembly point. Each half 25 or 27 of the assembly tool has double ends, end 29.31 of the symmetrical half 25, end 33 of the symmetrical half 27.
．． 35 respectively. As described in more detail below, the wire is of a double-ended configuration so that the wire can be inserted into the connector by either the left or right half of the assembly tool.

For convenience of explanation, the left half is resting, the right half R1 front F and rear R
The assembly tool 17 will be described as having the following. In this case, the wire transport tool is located behind the end effector. However, as will be described in detail later, this double-end assembly tool does not actually have front or rear parts.

The left "L" side portion of the rear assembly includes a mounting post 37 defined by the vertical L-shaped portion of the bracket 13. A V-shaped groove 43 is formed on the inner surface of this support 37, and a hole 4 extends outward from the bottom of the V-shaped groove 43.
5 passes through the strut portion 37.

A pneumatic cylinder 47 is attached to this hole 45, and its piston 49 protrudes from the V-shaped groove 43. Inner insertion clamp 51 into piston 49 of pneumatic cylinder 47
Attach. The inner insertion clamp 51 includes a V-shaped base 53 that seats in the V-shaped seat 43 in a first or retracted position. A jaw portion 55 formed at the base of the inner clamp 51 engages the opposite side of a second symmetrical inner clamp 51' on the right bracket. The interaction between the left hand inner clamp and the right hand inner clamp will be described in detail later. Selective actuation of the clamp grips and releases the wire held by the tool.

A pair of robots 57, 59 are slidably attached to the holes 39, 41 of the support column 37, respectively, and protrude in the longitudinal direction of the gripper. A first collet 61.61' is attached to the front end of the rods 57, 59, and a second collet 63.63' is attached to the rear right end of the rod 57.59. As can be seen from FIG. 2, each collet has a first and a second half, namely 61.61' and 63.61'. 63', the wires cooperate with each other to support and guide the wire to the NSI formation position. The collet is mounted on at least one of the rods on both sides of the column 37 as shown in the figure d.
A pair of springs 65,67 maintain it in a first or neutral position relative to the column. It goes without saying that the upper rod 57, the lower rod 59, or both the upper and lower rods may be provided with biasing means. With this configuration, in the process of inserting the connector pin, the column can be slid toward a predetermined collet, and then removed to the neutral position again. Each of the collets 61, 61', 63 and 63' has a groove 6
9, which grooves cooperate with the grooves of the opposing collet to form a hole through which the wire slides as the end effector 11 conveys the wire around the cedar board. Each collet also includes a pair of knife edges 71 which cooperate with the knife edges of the opposing collet to better align the opposing collets with each other and guide the wire. Collet pairs 61, 61' and 63.
To facilitate engagement and alignment of 63', at least one, preferably two, pin and hole alignment systems are provided.

A pair of holes 60 are formed in each of the collets 61 and 63 so as to be located above and below the groove 69, and a pair of holes 60 are formed in each of the collets 61 and 63.
A pair of pins 62 are provided on each of the pins 1' and 63', and are fitted into the opposing holes 61. The combination of pins and holes in each collet not only stabilizes the gripper, but also necessarily aligns each gripper half with the other half when the assembly tool 17 is in the closed position.

As shown, the mounting, movable in the disengagement direction with respect to each other, is achieved by mounting the working end 17 on the end of a known robot hand with a bracket 13.15, so that the inner clamp 51.51' is attached to the outer clamp of the assembly tool. The collets 61.61', 63.63' can be engaged with each other independently.

As shown in FIGS. 2 and 3, the wire pulling/6 erecting tool 19 at the working end 17 is
Mounting for independent movement along the axis maintains the central position of the wire feed mechanism for independent movement along the X-axis of the bracket 13.15 containing the jaw assembly. The tension/six-up tool 19 is mounted for driving along the Z-axis by at least one, preferably two, pneumatic cylinders 73, 75 mounted on the bracket member 77.

The bracket member 77 is mounted and supported by at least one, preferably three, pneumatic cylinders 79.81.83° mounted on the rearwardly projecting cantilever arm 23 of the bracket 13. Specifically, the bracket 77 is fixed to the piston of each cylinder 79, 81, 83 so as to be movable in the X-axis direction as shown by the chain line. Wire tension/
The main body portion of the six-up tool 19 is fixed to a bracket member 77, and a pneumatic cylinder 73.7 hangs down through the bracket member 77.
Tension driven along the X-axis by the piston of 5/6
This is a erecting device 87.

During normal operation of the working end, the pneumatic cylinder 7 is moved so that the tension/6-up device 87 is directed downward with respect to the bracket member 77, that is, in the first position in the Z-axis direction, that is, in the maximum protrusion position.
3.75 works. When the cylinders 73,75 are relieved of air pressure, the tensioning/sixing device 87 is retracted relative to the assembly tool 17 to a second or raised position. This elevation can be accomplished by utilizing biasing means, such as internal springs on the pneumatic cylinders 73, 75, or springs suspended between the bracket member 7f and the tensioning/erecting device 87.

A hole 91 passes through the wire tensioning/tightening device 87 of the wire tensioning/tightening tool 19, and the end of the hole remote from the assembly tool jaws is preferably formed in the shape of a funnel 93. By connecting (95) the pneumatic wire transport system to the tension/pull device 87, the connector bin can transport the clamped wire to the wire transport tool. A clamping means 97 is arranged within the tension/pull device 87 to clamp the wire "Woo" inserted by the wire supply means. The clamping member 97 consists of a pneumatic cylinder 99 with a piston 101 in communication with the clamping means 97. When the pneumatic cylinder 99 is actuated, the clamping member 97 descends and clamps the wire by pressing the wire against the bottom wall of the hole 91. The operation will be discussed in more detail below in the context of wire transport systems and wiring manufacturing.

The vertical cross-sectional view of the blank fixing clamp 111 is shown in Fig. 4, and the end
A simplified diagram of the tension/release device 87 of the effector 11 is shown in FIG. Fixed clamp 111 consists of a generally rectangular member 113 mounted to a cedar board as described below and includes a pneumatic piston 115 mounted in a hole 117 extending from base 119 to top 121 of the member. A contact insertion hole 123 is formed in a direction substantially perpendicular to the hole 117, and is dimensioned so that a contact pin ゛°P゛°, which is crimped to the end of a wire to be laid on a cedar board, is inserted therein. The hole 123 is countersunk (125) so that the crimp contact P can be inserted into the hole 123. The pneumatic cylinder 115 is provided with clamping means 129 at the end remote from the cylinder 115. When the contact P fits into the hole 123,
The pneumatic cylinder 115 is actuated to positively secure the contact P within the bore 123 by the clamping means 129.

A clamp 1 fixed to a cedar board 131 schematically shown in a plan view in FIG.
Install 11. Fixing clamp 111 is fixed to cedar board 131 at a location offset from the typical route followed during wire harness manufacturing. The manner in which fixed clamp 111 cooperates with end effector 11 will be described in detail below.

Referring again to FIG. 5, the alignment means are collectively designated by the reference numeral 13.
3, and as is clear from Fig. 6, the cedar board 13
They are placed in multiple positions on 1. These multiple positions are usually set near the connector where the wires are assembled. The alignment means 133 consists of a block 135 with a hole 137 formed therein so that the alignment means 133 can be positively but removably fixed to the cedar board 131 via a tightening screw or clamp (not shown). At least one alignment hole 141 is provided in at least one surface 139 of alignment means 133 . This alignment hole 141 allows the contact pin to be aligned with the collet of the assembly 117 before inserting the contact P into the connector by the assembly tool. A plurality of alignment holes 141, 143 may be provided on one surface 139 of the alignment means 133. Specifically, the alignment hole 141 consists of an elongated passageway 145 into which the contact P is inserted, and a counterbore portion 147 in which the collet end seats during alignment. The alignment hole 143 is sized according to the size of the connector pin to be inserted.

Any number of alignment holes can be provided with a variety of internal geometries to accommodate a variety of connector pins.

7-14 schematically illustrate some of the steps taken in manufacturing a wire harness according to the method and apparatus of the present invention, and also illustrate the operation of the end effector 11 shown in FIG. FIG. 15 shows a uNIMATE Series 6000 electric robot that can be used with the wire feeding system and end effector of the present invention in the manufacture of wire harnesses. In order to relate the schematically illustrated manufacturing steps to actual wire harness manufacturing, reference will be made from time to time to the cedar board shown in FIG.

Referring again to FIG. 7, in order to start assembly, the gripper 11 must first capture and grip the wire W to be inserted. The wire is cut to a predetermined length in the wire processing section, and both ends of the wire are trimmed.
Contacts are crimped on each end. As for this wire processing section, illustration and description thereof will be omitted here. The processed wire is conveyed by an automatic or manual system to a pneumatic system that conveys the wire toward an end effector for wire harness assembly. Reference numeral 149 in FIG. 7 is such a pneumatic wire conveying system, which includes a wire supply means 153, an air supply source 151, and a pneumatic supply pipe 155. After the processed wire is fed to the supply means 153, it is driven by pneumatic pressure to quickly and smoothly transfer it to the tube 155.
It passes through the wire and reaches the wire tensioning/six-up device 87. Each wire is charged into an introduction section, that is, a cofeeding means 149,
It will be sealed. The wire is then subjected to a wire pull/6 at an air back pressure of about 80 psi and a speed of about 25 feet/second.
It is transferred to the erecting device 87. To programmatically control air pressure, a series of Mack air valves were installed with parallel valve openings. The flexible tube 155 is made of low-cost polyvinyl chloride (PV).
It is preferable to use [:). The tube 155 connects at its end 95 to the tensioning/sixing device 87 of the gripper 11. The contact P of the wire W enters a fixed clamp 111 on the cedar board.

When the wire contact P enters the contact hole 123, the clamping means 129 engages the contact under the action of the pneumatic cylinder 115 (FIG. 4). In other words, after the wire enters the fixing clamp, the pneumatic cylinder is actuated to fix the contact pin P of the wire and position the wire to be picked up by the assembly tool 17. As is clear from FIGS. 2 and 7, at this point in the process, the jaws of the assembly tool 17, i.e., the left and right halves, are in a position that maintains a distance from each other, so that the gripper can move along the axis 8 times while moving the tube 155. The left and right halves of the jaw are fixed as the wire is fed into a tensioning/6erating device 87 which positions and erects the wire to be picked up by the assembly tool 17. Clamp 111
can span.

As is clear from FIG. 8, the tensioning/6erating device 87 moves away from the fixed clamp 111 along its axis, so that both the tensioning/6erating device 87 of the gripper 11 and the assembly tool 17 are on the same side of the fixed clamp 111. Located in The inner clamping means 101, shown in FIG. 3, of the tensioning/sixing device 87 is now activated to properly tension and position the wire. At this point, the assembly tool 17 is used to position the wire in the groove 69 defined by the left and right collets 61.61', 63.63' of the alignment tool.
The left and right halves of the are closed. Gripper collet 61.61'
closes on the shoulder S of the pin P, the fixed clamping means 129 ceases the clamping action and the gripper grips the wire. The wire will now be checked to see if it is in the correct position for insertion. The pair of collets 61, 61' at the front end of the gripper 11 engages with the crimp portion C of the contact pin P located behind the shoulder S and grips the crimp portion so that the wire can be conveyed to other positions on the cedar board. ing.

As is clear from the cedar board in FIG. 6, the gripper 11 is operated by an overhead robot and the fixed clamp 1
11 and conveys it to the first assembly point, connector 157. During this operation, the wire itself only moves with the gripper and is not conveyed through the tube. The proper position of the pin P for insertion is the alignment means 13 provided near the connector 157 on the cedar board 131.
Confirmed using 3. Although the alignment means 133 is shown mounted next to the connector 157, an integral mount may be provided to hold the connector and alignment means together. Actually, as shown in FIG. 9, the assembly tool 1 is inserted into the hole 141 formed to match the specific contact pin to be inserted.
7 inserts the connector pin P. The insertion gripper is temporarily opened while the alignment means accurately repositions the pin relative to the gripper in preparation for insertion. Once alignment is complete, the gripper jaws are closed and the assembly tool again secures the crimp portion of the connector within the hole 69.

10 and 11, the assembly tool is first aligned with the corresponding hole 159 of the connector 157 via the gripper 11. In FIGS. The robot presses the protruding pin P connector hole 15 until the strain gauge provided on the robot wrist detects an increase in force.
Insert into 9. Pin P does not enter the connector deep enough,
If a failure is indicated, the robot backs up and attempts insertion until the correct position is achieved, and if proper insertion is still not possible, it stops and signals the operator for assistance. When the connector pin P is correctly inserted into the hole 159 of the connector 157, the assembly tool opens slightly, resulting in the collet 61. defining the outer clamp.
61', 63.63' no longer engage the crimp portion C of the connector pin. At this point, the appropriate pneumatic cylinder activates the inner clamp 51 of the assembly tool 79, causing it to grip the wire. The robot arm now moves the column toward the assembly point, connector 157. As the robot arm moves laterally, the spring 67
is compressed. This compression action causes the strut to collet 61.6
1' and push the wire out to seat the pin at the assembly point. That is, as the post moves relative to the collet with the inner clamp 51, the wire is forced into the connector until the force sensing means indicates that the pin is fully inserted into the connector. This step can be repeated as necessary. Monitor the wire tension while retracting the tool to ensure proper insertion. If sufficient tension is not present, for example if the pin is not locked, the robot is programmed to attempt insertion again. Insertion check is accomplished by gripping the wire with inner clamping means 51 and moving the robot slightly in the opposite direction to the insertion direction to check whether proper tension is present, as shown in FIG. be done.

Once insertion is confirmed, lay the wire along the cedar plank layout while feeding the wire to the opposite end of the tool. As is clear from FIG. 6, this laying takes place from the connector 157 through the insulators 161, 163 to the alignment means 133 provided in the vicinity of the connector 165. For convenience of explanation, the third alignment means 133 is shown near the connector 167. The specific arrangement of the wires in the wire harness is one of the manufacturing conditions and varies depending on the use of the wire harness itself. Accordingly, any number and variety of tethers and connectors may be used in the gripper apparatus and method of the present invention. During the course of wire laying, several collets come close together to define holes 69 and inner clamp 51 is disengaged from the wire. The wire passes through this hole 69 as it is delivered from the tensioning/sixing device 87. During installation, monitor wire tension to detect slack or tangles. Once the correct installation has been completed, the second end connector pin P of the wire W drawn out of the hole 69 is automatically inserted and engaged with the collet pin 63, 63'.

As shown in Figure 14, wire insertion at the second end is also detected by force sensing means. When the shoulder S of the contact pin P reaches the collet pair 63, 63' of the assembly tool 17,
Wire tension increases and strain gauges in the robot hand indicate contact bin insertion. If the strain gauge detects this, the second end of the wire is pulled/6-up device 8
It is clear that he has left the 7. As a result, air pressure is released from the several cylinders 73,75 that maintain the tension/6 erecting device 87 in the downwardly protruding position, and the tension/6
The upright device is spring biased to a second or raised position. When the lining/sixing device is in the raised position, the second or rear end of the assembly tool defined by the collet pins 63, 63' approaches the alignment means 133 and the connector 165 in its vicinity. As already explained in detail,
The robot gripper pushes the protruding pin P at the second end of the wire into the alignment means for repositioning if necessary.

At this point, the wire is ready for insertion into the second connector. The movements required for insertion into the second connector are similar to those required for insertion into the first connector. Note that any number of connectors of different types can be used. However, if the pins are of different sizes and therefore require different forces for insertion, the programmable robotic system will adjust the force sensing means to accommodate this new situation. Once the pin is inserted, again perform a post-insertion pull test to ensure that the pin is properly locked within the connector. Please refer to FIGS. 9, 10, and 11 and related descriptions for details of the pin alignment and insertion procedure.

Given the complexity of wire insertion in automated assembly of high density wire harnesses, there is a need to integrate sensors with assembly tools. Since such sensor integration is already known and implemented in many commercially available robots, the operation of the strain gauges will not be described in detail here. Strain gauges are often utilized to provide the sensor input necessary for this type of assembly operation. Therefore, the insertion and installation utilizes a force monitor, and this force is monitored by the computer through the use of strain gauges. The strain gauge output or force is represented in the program as a variable that can be accessed at any time to determine the force applied to the gripper. Prior to insertion, the gripper verifies that the path is clear by monitoring the force exerted on the terminal wire end as it approaches the connector. During the insertion process, force feedback is used in conjunction with position feedback to detect when the pin is fully inserted into the connector. Once the force shows a predetermined increase, check the position to ensure that the pin is properly seated within the connector. Once inserted, the gripper retracts and pulls the wire. The force is then checked again, and if the pin is found not to be locked in the connector, reinsertion is attempted in a new passage. If the proper force is sensed, assembly can continue. Complete the assembly, i.e. wire 2nd
In order to insert the end, the terminald second end must be positioned. The gripper moves along the axis with the wire until an increasing force causes the second end to be gripped by the gripper, indicating that it is ready for insertion. The use of sensors in the assembly process as described above not only provides a measure for error correction, but also helps position the wire end for insertion into the wire insertion gripper second end. An effective tool is also provided to ensure insertion. Such a strain gauge is an endpoint of the present invention.
It can be incorporated into a flexible wrist or robotic hand that grasps and actuates the effector. This wrist or hand is commercially available, and the use of strain gauges to monitor wrist or hand movement is well known to those skilled in the art of automatic manufacturing.

A wire piece manufacturing apparatus 400 of the present invention is schematically illustrated in FIGS. 16 and 17 together with a control device 402. This control device 40
2 is referred to in FIG. 16 as computer means 12;
The portion of computer 12 that controls the wire manufacturing apparatus will be referred to as controller 402. The control device 402 can also be a computer means separate from that used to control the cable harness assembly equipment, but in each case the manufacturing and design database is integrated into both the wire manufacturing equipment and the cable harness assembly equipment. It acts as a control device for the Manufacturing data regarding wire segments manufactured in batch mode or in sequence mode to form matched wire segments for a cable harness is provided to a controller 402 operatively connected to wire segment manufacturing apparatus 400 . Input via line 404. The control device may be composed of a plurality of microprocessors or general purpose computer means, and is configured to control and operate the wire piece manufacturing device and the individual processing sections forming the same.
Control signals are provided via lines 406-409.

The purpose of the wire piece manufacturing device is to cut wire of any diameter to a predetermined length, send the wire pieces along the device to various processing sections, and form arbitrary electrical terminals and identification markings on the wire pieces. It is in. The produced piece of wire is ready for use as material for a cable harness such as that described in my US patent application Ser. No. 670.528 (filed November 13, 1984).

In FIGS. 16 and 17, which show a wire piece manufacturing apparatus having a substantially rectangular shape and having processed parts sequentially arranged at intervals along its periphery, the first processed part is located at the lower right corner. A rectangular central work area contains the workpiece (not shown).

The wire line manufacturing device functions as follows.

The cut wire 411 (FIG. 17) is connected to endless chain means 416 and multiple sprockets 418.4.
19.420.421 Wire piece container 41 mounted on a transport pallet 414 movable around the central working area
A pallet for conveying a wire piece is advanced from processing section to processing section arranged around the central working area, and in each processing section, a specific wire piece processing operation is performed on the pallet for each processing section. In the embodiment of FIG. 16, there are a total of 32 machining sections.

As is clear from FIG. 17, the rectangular central area 410
drive sprocket members 418.41 located at each corner of the
Chain 416 advanced by 9.420.421
A plurality of pallets, typically designated by reference numeral 414, are attached to the pallet. A container 412 attached to each pallet holds a piece of wooden wire with both ends protruding. For details on wire transport pallets and wire containers, see Section 20.21.
and Fig. 22, and details of the driving means are shown in Fig. 18 and Fig. 1.
It is shown in Figure 9.

The first processing section 422 located in the lower right corner of FIGS. 16 and 17 is the wire delivery/cutting section. A plurality of wire delivery/cutting sections 422-426 are provided so that wires of different diameters can be delivered as required. These wire delivery/cutting stations are shown in detail in FIGS. 32 and 33.

A single wire 411 of a predetermined diameter is supported at its ends 413, 415 in first and second clamps and extends a predetermined distance from the clamps generally parallel to each other toward the workpiece, as shown in FIG. The wire is sent from the processing section 422 to the wire container 420 in this manner.

The wire delivery/cutting section is shown in detail in FIGS. 32 and 33.

A single piece of wire 411 of a predetermined diameter is fed from delivery section 422 into wire piece container 420, as schematically illustrated in FIG.
Connect both ends 413 and 415 of the wire pieces to the first and second wires.
They are supported by clamps and project a predetermined length from each clamp in a manner substantially parallel to each other.

A wire transport pallet 4 with wire pieces held in a wire piece container and supported by first and second wire clamps.
14 is sent to a wire straightening processing section 428, where the wire end protruding from the wire clamp is straightened, and the wire ends 413 and 415 are supplied to the subsequent processing section. is set at a predetermined interval. This wire straightening processing part 428 is
This is shown in detail in Figure 0.

In FIG. 16, a pre-processing section 430 is next to the wire straightening section 428, and a wire stripping section 432 is next thereto. This stripping processing section 4
32 removes the electrical insulation from a predetermined length of the protruding end 413, 415 of the wire piece. The next processing section is the wire stripping verification section 434, where a TV image of the ends 413 and 415 of the wire 412 is formed and analyzed to ensure insulation. It is detected whether or not the end portion 39 is removed.

In the wire stripping section 432, the ends 413, 415 of the wire piece 412 are sequentially stripped. That is, when the first end 413 is placed in front of the stripper and the wire clamp holding the first end moves outward to insert the first end 413 into the stripping section 432, the stripping operation is performed. . A horizontal indexing means included in the wire conveying pallet is connected to the other end 4 of the wire.
15 is indexed in front of the stripper 434, and the above operation is performed on this second end.

When it is confirmed that the wire piece 412 has been correctly stripped, the wire conveying pallet holding this wire piece is advanced to the next wire piece processing section. If the stripping operation is not performed correctly, the pallet with the incorrectly stripped wire pieces may be sent to the discharge station without further processing, or the operator may intervene to remove the A signal is sent to controller 402 so that the ripping process can be completed.

Further processing may or may not be used depending on the type of terminal placed at each wire end. The control device tracks the wire pieces at each processing station and provides control signals to the appropriate processing station for proper wire piece manufacturing operations and terminal formation. The wire terminations may be formed as pin contacts, eyelets or U-type terminal lugs, or any type of terminal means insertable into electrical connectors. Has a working part space, working parts 436 to 468
each perform a specific task to attach an electrical terminal to a piece of wire. Working portions 436, 438 and 440 are lugs or contact mounting/forming portions. The working section 442 is a solder flux applying section, and the working section 444 is a solder applying section that applies solder to the wire ends coated with flux in the solder 7 flux applying section 442. Working part 4
46 is a cleaner section for removing excess flux from the ends of the wires coated with solder. Working section 450'EL4
Reference numeral 52 denotes an electrical terminal attachment/formation section different from the working sections 436-440.

Working stations 454, 456 and 458 are further terminal mounting/forming stations. Working portion 460 is a spare working portion, and working portions 462, 464, 466, and 468 are further terminal forming portions. These working sections 436-468 are for attaching/forming the required terminals to the required wire ends. Under the control of a control device, each wire piece is transported held in a wire piece container on an individual wire transport pallet, where the necessary terminal formation is carried out on each wire end according to the wiring conditions, wire piece design and manufacturing data. Proceeding next to tensile testing section 470, the integrity of the electrical terminals or contacts at each wire end is tested.

Confirm that the terminal and wire body are securely connected both mechanically and electrically by holding both the terminal and the wire body and pulling in the longitudinal direction of the wire piece.

This wire tension test section 470 is shown in detail in FIG. .

The wire piece then passes through the inkjet marking section 472.
Proceed to. Spray identification markings on the insulation near each wire end. The identification markings are controlled by controller 402, and the identification code corresponding to each wire end is determined by wiring design and manufacturing data.

The piece of wire with the inkjet marking is advanced to the ink drying section 474 and heated to dry the ink to complete the wire identification marking.

In the embodiment of FIG. 16, there are two ejection sections 476, 478, which together with another spare working section 480 make a total of 32 working sections. At the wire discharge station, the wire that has completed its manufacture and is circulating through the wire manufacturing apparatus can be removed from the apparatus and transferred directly to a cable harness assembly apparatus such as that disclosed in the above-mentioned US patent application. This transfer can be accomplished by a simple robotic arm having an end effector that engages at least one end of the wire strip, removes it from the wire strip container, and feeds it directly into the cable harness assembly equipment. While the wire piece remains in the wire piece container, the container may be removed and both may be transported and stored together or fed directly into a transport assembly device. A robotic arm end effector may be engaged with both ends of the wire to remove the wire from the wire piece receptacle and then feed one end directly into the cable harness assembly apparatus or once into a storage means. It goes without saying that the number of working sections can be arbitrarily set, as well as the function of the specific working section for manufacturing wire pieces.

FIG. 17 shows a wire piece transport pallet and a chain/sprocket drive for circulating the pallet for wire manufacturing equipment. Both ends of the wire protrude toward respective work stations aligned with the wire piece conveyor pallet. In each work station, the wire ends are fed separately or together towards the work station by actuating a wire piece transport pallet by means of a control device, and the ends of the wire are transported in a defined manner to carry out the wire manufacturing operation. It can be indexed horizontally at regular intervals on both ends of the wire to be fed to individual working stations.

Although the operation of the apparatus according to the invention has been described above with respect to the processing of a single piece of wire, each working station can carry out its assigned wire piece production task independently of all other working stations. That is, pieces of wire that require processing to produce pieces of wire are arranged in a plurality of work sections, and the control device 402 controls all operations that must be performed to produce pieces of wire, and all operations are performed individually. The transport device is prevented from indexing until the work is completed. Therefore, in any case, the working station with the longest cycle time controls the indexing interval.

Figure 18 shows one of the sprockets supporting the drive chain and the main support (structure) 62 shown in the top view of Figure 17.
FIG. 3 is a partially sectional view showing the relationship of the sprocket to zero. Each sprocket includes a top and a bottom, with the top consisting of an inner circular member 601 and an outer ring member 600. The bottom consists of a single circular member 602, and the top and bottom are spaced apart from each other via a cylindrical spacer 604. The sprocket image portion is secured to the spacer 604 by suitable means such as screws.

The bottom member 602 of the sprocket is fixed to a flange member 606 which is fixed to a hollow shaft member 607. Upper and lower bearing 608
．． 610 supports the hollow shaft member 607, and both the upper and lower bearings are fixed to the support plate 612. Support plate 612 is supported by the remainder of support structure 620. The support structure 620 includes leveling devices 622,624.

The structure described above is almost the same for each of the driving sprockets shown in FIG. 17, but in the case of FIG. 17, by interlocking the hollow shaft member 607 and the motor at one corner, The chain transport mechanism can be driven in indexed walkway fashion along the path shown in FIGS. 16 and 17. Controller 402 activates the drive motors to position wire strip transport pallets in a walkway fashion at respective workstations where required wire strip processing is to be performed.

FIG. 19 is a top view of the sprocket mechanism shown in FIG. 18, showing a portion of the table top structure 630 around which the various working parts are arranged, as well as devices for supporting the drive chain. Guide 6 arranged along the straight line of
26.628 is also shown. The diameter of the drive sprocket shown in FIGS. 18 and 19 is approximately 3 feet, and the length of the transport chain links is approximately 1 foot. Therefore, the effective path length around the sprocket is reduced because the chain does not conform to the outer circumference of the sprocket. That is, the links of the chain form line segments connecting the notches of the sprocket 600. If this reduction is not compensated for, the pull on the drive chain can vary depending on the rotational position of the drive sprocket. To compensate for this reduction, the grooves 626, 628 do not approach the drive sprocket 600 tangentially in a straight line, but instead curve inward and then outward just before the sprocket, allowing the chain As the drive pin approaches the sprocket and moves away from it, the chain drive pin moves slightly inward.

With this configuration, an effect can be obtained in which the sprocket rotates to index the chain and maintain a constant tensile tension acting on the chain during the process of positioning the wire conveying pallet in the work area.

Vertical support rollers 734, which support the drive chain vertically along straight edges, move on the top surfaces of roller guides 626, 628. As the vertical support roller 734 approaches, it transitions from the top surface of the sprocket support member roller guide 628 to the support block 735 fixed to the top surface of the ring member 600. Since the vertical support rollers 734 are provided between the multiple pairs of wire piece conveyance pallets 414, a vertical support block 735 is provided for every two notches of the ring member 600.

As already mentioned, the function of the wire piece transport device is to transport pre-cut wire pieces in a defined manner to the various working stations. Specifically, as is clear from FIG. 19, the wire piece transport pallets 414 are fixed at positions equidistant from the transport chain, and each wire piece transport pallet 414 is connected to the first and second wire support clamps 656.
．． 658 and the first and second ends 413.4 of the wire piece.
15 project outwardly from said clamps 656, 658, respectively. The wire piece is attached to a wire support clamp 656.
A round container 649 with a tabular edge protruding from 658 (
It has a coil shape on the inside (Fig. 20). Wire support clamps 656,658 are secured to generally rectangular first and second plate members 660,662, and the rectangular plate members 660,66
2 is fixed to two other plates not shown in FIG. 20 so that rectangular plate members 660 and 662 can independently slide forward. However, the rectangular plate members 660, 662 are normally held in the retracted position by coil springs 661, 663.

Two L-shaped bushing brackets 666.668 are secured to the ends of the rectangular member 660.662 opposite the wire support clamps 656.658, and the support brackets 652
A bushing bar 670 is slidably attached to the top by two support rods 668 and 669. An actuator (not shown) pushes the bushing bar 670 into contact with the bushing bracket 668,667, thereby pushing the wire support clamp 656,658 and thus the wires 14413,415 a fixed amount. 20th
In the figure, bushing bar 670 contacts both U-shaped bushing brackets 666, 668 and wires 41
The length is selected to push the ends of 3 and 415 forward a predetermined amount. The extruded wire ends are positioned so that the working section can perform wire piece manufacturing operations such as stripping and labeling, which will be described later. In both working stations, a wire transport pallet 414 holding pieces of wire with wire support clamps 658, 660 is placed in front of the working station, and when the wire support clamps are pushed out, the wire ends 413, 415 are attached to the working station. It is configured to be located within the working range.

Figure 21 shows another embodiment of a mechanism for pushing out wire support clamps 656, 658 to feed wire ends 413, 415 to the working station. Here, the length of the bush bar 670 is set shorter than the distance between the bush brackets 666 and 668, and the clamp holding mechanism is
A bushing bracket 666 attached to bushing member 60 is positioned in front of one of the ends of bushing bar member 670. Even if the bushing bar 670 is pushed out, the second end
No contact with bushing bracket 668. That is, the first end 415 of the wire piece is simply pushed out so that it faces the working area of one or more working parts. Wire support clamp 55 so that second clamp member 658 is pushed out.
The arrangement of δ, 658 may be changed. Therefore, as is clear from FIGS. 20 and 21, the wire piece is inserted into the container 666.
It depends on the individual whether the wire pieces 413, 415 are stored in the wafer and transported in a defined manner to each working station, what operations are performed to produce the wire pieces, and whether the wire ends 413, 415 are extruded to the working stations separately or together. determined by the function of the working section.

22 and 23 show wire support clamp 660.
662, also showing details of the support structure that attaches these wire support clamps to the transport chain. 22 and 23 differ from each other in that FIG. 22 also shows other parts of the conveying chain. That is, whereas FIG. 7 shows two complete conveyor chain links, FIG. 23 shows one link and parts of two other links.

The wire support clamp 656 is the wire support clamp 6
It is a mirror image of 62. The wire support clamp 65δ includes a top and a bottom with a groove for locating the wire end at the intersection. The bottom of the wire support clamp 656 is fixed to the top surface of the rectangular plate 660. Clamp 6
The bottom of 56 includes an opening for passing rod 714 and securing it to the top of wire support clamp 656. The cylindrical portion 712, like the rod 714, is secured to the bottom of the rectangular plate 660. The coil spring 716 is attached to the rod central portion 7
14 and is in contact with a flange portion 717 fixed to the lower end of the cylindrical portion 712 and the lower end of the rod 714. This spring normally biases the wire support clamp 656 into one piece to support the wire end disposed in the groove. To release the clamp 656, a suitable button is provided to push up the flange portion 717.

In FIGS. 22 and 23, the second wire support clamp 658 is hidden from view in order to clearly show the structure below. That is, by showing the rectangular portion 662 in cross section, it has been made clear that the bottom of the rectangular plate 662 includes a groove portion.

Two plain bearings 704, 706 are arranged in the groove, the inner part of these bearings being fixed to the plate 702 and the upper part to the rectangular plate 662, respectively. Therefore, by pushing out the rectangular plate 662, the wire support clamp 658 fixed thereto can be pushed out, and the wire held by the wire support clamp 658 can be positioned in the work section where wire manufacturing work is performed. . Similarly, plate member 660 is a mirror image of plate member 662, and although not shown in detail in FIGS. , rotate outward to remove the wire support clamp 65
6. Attach to the support top plate 708 so that the distance between 658 and 658 can be increased. In the normal state, the wire support clamps 656, 858 are connected to the 22nd coil springs 701 with both ends fixed near the front of the plates 700, 702, respectively.
It is held in the position shown in the figure.

As discussed above, plates 700, 702 are rotatably attached to support top plate 708 near their inner rear corners. Top plate 708
is also attached to a vertical plate 718 that is slidably attached to the first link 719 of the conveying chain. A coil spring 722, secured at both ends to the links of chain 719 and spring bracket 720, holds vertical support plate 718 in the rightmost position, as seen in FIGS. 2 and 23.

There are two types of chain links, each type being identified in FIG. 22 by reference numbers 719 and 738. Each chain link is connected to an adjacent link via a pin 736. Representative pins are shown in Figure 22 with reference numeral 736.
It was shown in Pin 736゛ connecting chain links
pass through the links and have rollers 724, 726 attached to each end. Along the straight edges of the system, rollers 724, 728 move in tracks to hold the conveying chain in a generally vertical position and to keep said chain running in a straight line. A vertical bracket 732 attached to the central web of link member 738 stands upright above upper track 730 and extends above track 730.
30 includes a vertical support roller 734 that moves along the top surface of 30 . The bracket 732 and the vertical support roller 734 support the conveyor chain vertically to prevent it from sagging.

FIG. 24 is a top view corresponding to FIG. 23. As is clear from the figure, the rectangular plate 660.662 to which the support clamps 65B and 6513 are attached is the plate 700.70.
It is slidably installed on top of 2. 2 coil springs 750
．． 752 has plates 680, 662 and 7 at each end.
It is attached to 00.702. In normal conditions, the two springs 750, 752 are attached to the wire support clamp 656.
658 is held in the position shown in FIG. As previously mentioned, plate 700.7.02 is rotatably mounted near its rear inner corner and is held in an inward position by spring 754 mounted near the forward end of said spring 750.752. For completeness of illustration, bushing brackets 666, 668 attached to top plates 660, 662 are also shown in this top view. A vertical plate 718 is also attached to the support plate 708 and the assembly is slidably attached to the links 719 of the conveying chain as previously described. The pins for attaching the links of the transport chain are designated by the reference numeral 736, and the exemplary vertical support rollers located in the upper track 730 are designated by the reference numeral 734 (FIG. 22).

FIG. 25 is a top view corresponding to FIG. 24, showing the right wire support clamp 656 in a protruding state.

Extending the clamp 656 is accomplished by actuating the bushing rod 669 to push the bushing plate 670 until it contacts the bushing bracket 666 which pushes the top plate 660 along its sliding mound and extends the retaining spring 750. . Other than this protrusion, FIG. 25 is almost the same as FIG. 24, and common reference numerals have been used to identify each part.

The wire support clamp 658 is the wire support clamp 6
Since it is in a mirror image relationship with 56, the wire conveying pallet 41
4 can be similarly extruded by positioning it horizontally.

By horizontally moving the vertical support plate 718 and the wire support clamps 656, 658 attached thereto, the wire pieces 413, 415 held by the wire support clamps 658, 660 can be positioned at will. Plate 718 is slidably attached to chain link 719.

In FIG. 26, a rearwardly projecting bracket 761 to which a first end of a spring 763 is attached is attached to the left end of the vertical plate 718. The second end of the spring 763 is normally connected to the plate 7.
It is attached to a chain link 719 that holds 1B in the rightmost position. A stopper piece 765 is attached to the left end of the horizontal translator including the bar 760. A pneumatic cylinder 764 is attached to the right end, and the piston of this cylinder
Attach the bushing 766 to the rod end. Support plate 7
A pneumatic cylinder 762 is attached to 76 to move the bar 760 back and forth. In the pushed-out state as shown in FIG. 11, the restraining piece 765 restricts the movement of the support plate 718 to the left, while the button shear 766 comes into contact with the left end of the plate 718 as the pneumatic cylinder 764 operates. 718 to the left. Two extremes of f5 U of pneumatic cylinder 764 are sensed by two sensors 778 and 780, respectively, and provide signals indicative of the position of plate 718. The support plate 718 is the bar 76
Two other sensors 770 detecting the two extreme positions of 0
．． 772 is attached to the bracket 774.

Therefore, the support plate 718 and the wire support clamp 658
．． A mechanism is provided to move 680 between two positions and to sense these positions.

FIG. 27 is a front view of the mechanism shown in FIG. 266. As can be seen from this figure, support bracket 776 supports bar 760 and pneumatic cylinder 764 in a fixed position, in part by attaching bracket member 776 to table top 777 of the system. That is, the bushing mechanism is held in a fixed position and the wire support clamp 658.6
60 is secured by a drive chain indexing system that conveys. Accordingly, by actuating the pusher mechanism 764, the wire support clamp can be moved between the left and right end positions to alternately expose the wire pieces 413, 415 to the various wire manufacturing operations of FIGS. 28 and 29. shows the relationship between the wire clamp button mechanism and the wire support clamps 658 and 660. Second
8 shows the right wire support clamp 658 in cross section. This clamp is attached to top plate 660.

A spring 750 attached to the bottom plate 700 acts to hold the plate 600 in the rightmost position (in FIG. 28). board 66
The butcher bracket 6δ6 is attached to the top of the 0.

Structural member 654 is part of the fixed (non-movable) structure of the system. A second intermediate bracket 653 is attached to this bracket, and a button shear mechanism is attached to this. Specifically, the bushing bar 670 is attached to the bracket 652 by two sliding guide rods 667,669. This guide rod is supported by a bracket 652 via two guide bushing mechanisms. In the figure, 671 is a guide rod 669
This is a bush for. Pneumatic cylinder 673 includes a piston rod 675 that extends through bracket 652 and is attached to bushing bar 670. Therefore, when the pneumatic cylinder 673 is actuated, the button shear bar 67
0 advances and contacts pusher bracket 666;
Move the wire support clamp 658.860 to the extended position. Also included are sensors that generate position signals that are provided to control system 402 (FIG. 16).

FIGS. 28 and 29 also show guide tracks 730 for rollers 724. FIG. Plate 70 on link of chain 719
Also shown is a plain bearing mechanism 737 securing 8. Similarly, the bracket 732 has a roller 734 in the guide groove 730.
The guide rails 730 project inwardly over the top surfaces of the guide rails 730 to maintain the chain links in a vertical position.

FIG. 16 is a detailed view of the transport chain element, wire support clamp release mechanism and clamp button.

Wire support clamp 656 is shown in an advanced or extended position. Pusher pneumatic cylinder 673 (first
8) is actuated to push pusher bar 670 to the forward position. In this position, pusher bar 670 contacts pusher bracket 666 and moves top plate 660 to the advanced position. As a result, coil spring 750 is in an expanded state as shown.

As is clear from the above description, the top plate 660 is slidably attached to the lower plate 700. Plate 700 is attached to plate 708 via a pin/bearing mechanism 810 that allows the plate to rotate relative to support plate 708.

FIG. 30 also shows the cylinder 800 that releases the wire support clamp 656. This is a pneumatic cylinder with a plunger 802 placed in contact with the lower end of bushing rod 714. This bushing rod connects to the top of wire clamp 656. When the pneumatic cylinder 800 is activated and its plunger is raised, the coil spring 714 is compressed, causing the top of the clamp 656 to rise and open the wire support clamp 656.

Wire support clamp 656 at the location where the clamp must be released to perform the necessary wire manufacturing operations.
．． 658 is operated in a defined manner. i.e. reference number 8
A pneumatic cylinder, designated 00, is placed at each work station requiring opening of the wire support clamp. Control system 402 (16th
Also included is a position sensor that generates a position signal that is provided in the figure. It is necessary to provide an indexing means at a suitable location on the working station which positions the wire support clamp relative to the working station more accurately than the main drive indexing mechanism for the transport chain. For example, wire delivery/cutting operations require accurate horizontal and vertical positioning. Such precise horizontal positioning is achieved by forming index holes 804 in vertical plate 718. Once the conveyor chain has been indexed to a desired work station, positioning pins 806 are inserted into holes 808 by actuating pneumatic cylinders 808 mounted on the main structure of the system to precisely position the entire wire conveyor pallet horizontally. Gimme.

FIG. 30 also shows how the entire mechanism is positioned horizontally with respect to the chain links by positioning the plain bearing mechanisms 737, 739 between the plate 718 and the links of the chain 719.

FIG. 31 is a partial top view of FIG. 30 showing the positioning of the indexing mechanism relative to the vertical plate 718. Operation cylinder 80
8 is attached to a bracket 818, and the bracket 818 is attached to the structure of the system. Two sensors 814, 816 (not shown in FIG. 30) sense the two positions of locating pin 806 and provide signals indicative of this position to control system 402 (FIG. 16). Specifically, a sensor 816 indicates the point of insertion of the pin, and a sensor 814 indicates the point of withdrawal of the pin. Therefore, the horizontal indexing mechanism shown in FIGS. 30 and 31, which allows very accurate horizontal positioning of the wire support clamp by actuating a locating pin, is suitable for any work station requiring this feature. It has excellent versatility in that it can also be installed.

FIG. 32 is a side view of the wire delivery/cutting section 422 that supplies wire pieces to the wire conveying pallet 414. The wire 900 supplied to the wire conveying pallet 414 is normally stored in rolls (not shown). The wire 900 first passes through two pairs of orthogonally arranged straightening rollers 902 and 904. After passing through the straightening rollers 902 , 904 , the wire 900 passes through a measuring device consisting of a wheel 906 of known diameter, a rotating cog attached thereto, and a tension wheel 908 that presses the wire 900 against the wheel 906 . The wire 900 passed through the measuring device is connected to two drive wheels 9
10, the drive wheel 910 pushes out the wire 900 while rotating, and passes through the two shear blocks 9.
12.914, passing through open clamp 756, wire reversing mechanism 918, and then passing again through shear block 914.912. The wire reversing mechanism includes upper and lower parts that are movable upwardly and downwardly, respectively. After passing the wire through the shear blocks 912, 914, the pneumatic cylinder 920 is actuated to lower the lower portion of the wire reversing mechanism 918.

The top plate (upper part) is provided with a suitable mechanism for raising it. After raising and lowering the upper and lower parts of the wire reversing mechanism, respectively, as described above, one of the wire support clamps is closed to grip the wire, and the other wire support clamp 658 is opened. The wire delivery unit drive mechanism 910 is operated to insert a wire of an appropriate length into the wire conveyance pallet 414. Both wire support clamps 656, 658 are then closed and the pneumatic cylinder 9
Shear block 912 by actuating 16
is raised, and the wire 900 is cut at the position where these two blocks intersect. A flexible tube is provided to guide the wire between the drive mechanism 910 and the shear block 914, and the wire 900 is configured to pass through the tube.

FIG. 33 is a top view of the wire delivery/cutting section 422 and wire reversing device. In addition to the various components described in connection with FIG.
Also shown are a curved groove formed in the top plate 930 and a top plate 930 overlapping the bottom portion. Also, the wire 900 that is extruded into the supply port 910 and is formed while passing through the shear block 912, 914 and the groove of the wire reversing device.
A U-shaped curvature of is also illustrated. Furthermore, two plungers 924 operated by pneumatic cylinders to release the wire clamp during wire loading;
926 is also shown.

FIGS. 34 and 35 are a front view and a detailed top view of the wire reversing device, respectively. Both figures also show the reversing groove and top plate formed on the bottom of the wire reversing device 928. Also shown in FIG. 34 is a pneumatic cylinder 920 that drives the lower half of the wire reversing device up and down as described above. Sensors 931, 935 generate signals indicating the position of the wire reversing device. Similarly, sensor 94
1.943 is wire clamp release plunger 926
form a signal indicating the position of the Sensors 937, 939 generate signals indicative of the position of wire clamp release plunger 924. The output signals of these sensors are sent to the control system 402 (FIG. 17), which in response generates signals to actuate the wire delivery/cutting section 426 and the wire reversing device.

To explain the operation of the wire reversing device, as the first stage of wire loading, the butcher cylinder 67 shown in FIG.
3 and pusher bracket 6 shown in FIG.
86, H89 moves the wire support clamps 656, 658 so that they are just in front of the forward shear block 914, as shown in FIG. The lower part 918 of the wire reversing device is also connected to the 32nd
A pneumatic cylinder 920 is used to raise the
Take advantage of. Once the lower part 918 of the wire inverter is raised, the upper part 918 of the wire inverter is lowered as shown in FIGS. 32 and 33. Clamp release solenoid 924.92B is then actuated to open wire support clamp 658.660. Once the wire reversing device and wire support clamp are positioned as described above,
By actuating the wire drive mechanism 910 shown in FIG. 25, the wire 900 is fed through the shear block 912, 914, the inverter U-shaped portion, and then through the shear block 914, 912 again.

Pneumatic cylinder 924 is then actuated to close wire clamp 756 as shown in FIG. Cylinder 920 is used to lower the lower half 928 of the wire inverter and a suitable mechanism is used to raise the upper half 930. By activating the wire drive mechanism again, more wire is fed through the wire support clamp 658, and the excess is accumulated in the wire container 649, as shown in FIG. Once the appropriate length of wire is loaded, close the second wire support clamp 658,
Rear shear block 9 by pneumatic cylinder 916
12 is raised to cut the wire 900 at the interface between both shear blocks 912 and 914. A pusher mechanism is then utilized to retract the wire support clamp to the normal position shown in FIG.

Figure 36 in the margin below is a side view of the wire reversing device. As seen in this figure, a nut 923 is utilized to secure the piston rod of the pneumatic cylinder 920 to the vertical support member 918 of the wire inverter lower portion 928. An upright member 918 is slidably secured to the second support member 915 . This member is ultimately fixed to the plate mechanism 917 using screws. The plate 917 connects to the second vertical member 919 and the second vertical member 91
9 are respectively attached to the base support mechanism 921. The base support mechanism 921 is fixed to the abutment of the system. Two position sensors indicate whether the wire reversing device is in the raised or lowered position. Two air inlets alternately detect whether the mechanism is in the raised or lowered position.

When the wire support clamps 856, 658 and the wire reversing device are secured in the wire loading position into the container as described above, the wire drive mechanisms of these clamps are precisely aligned with the wire holes in the shear block 914. Preferably, the support clamps 856,658 are provided with vertical support members. For this purpose, as shown in FIG. 37, a substantially flat plate 950 is attached to the top surface of the front shear block 914. Two grooves are provided near the edges of this plate into which L-shaped brackets 949, 951 are attached.

With the two rollers 952,954 attached to the arms 949,951 and the wire support clamps 656, 658 positioned near the forward shear block 914 as in the wire loading position, the wire clamp 65
8 , 658 are attached to the plate 660 , 662 which abuts the top surface of the roller 952 , 954 and connects the grooved portion of the wire support clamp 656 , 658 to the shear block 9 .
Hold it approximately aligned with hole 14. This results in
Vertical alignment of the wire clamps required for wire loading is achieved. Accurate vertical alignment is obtained by vertically adjusting arm portion 949,951 relative to plate 960 using two screws 953,955. Also,
Horizontal alignment bins 806 (Figure 30) are utilized to provide approximately accurate horizontal alignment.

In order to more accurately show the configuration of the plate member 950 and arms 949,951, a side view corresponding to FIG. 38 is shown in FIG. 39.

In the process of loading the wire into the wire support clamps 656, 1158, the wire inversion device universally leaves some degree of curvature in the wire ends 413, 415. When using the device of the invention, the wire ends 413.41
It is highly desirable that the wire supporting clamps 656, 658 project a predetermined distance outwardly from the wire support clamps 656, 658 and are supported by said clamps at substantially right angles to the wire clamps. Wire support clamp 656.658
That is why a wire straightener must be utilized to straighten the wire after loading. Device 42 for straightening wires
8 is shown in FIG.

Wire straightener 428 is described below in connection with a single wire held by wire support clamp 656. Since the wires held in each of the wire support clamps are straightened separately in exactly the same manner, only a single wire will be described.

As a first step in the wire straightening process, the wire support clamp 6 is moved using the bushing bar 670 so that the wire to be straightened is positioned between the jaws 1000 and 1002 of the wire straightener 428.
56 to the forward position. Once positioned within the grip of the jaws, pneumatic cylinder 1014 is utilized to pull rod 1018 to the position shown in FIG. In this position, the flange on the end of rod 1018 is aligned with jaw 1000.
．． 1002 to close the front portion of the jaw tightly against the wire. electric motor 1010
is interlocked with the pulley 1012, and the pulley 1012 is interlocked with the shaft portion 1004 via the pulley 1006, thereby rotating the jaws of the straightener. Once the wire is positioned between the jaws of the straightener and the jaws are closed and rotated, the wire support clamp 656 is pulled away from the front portion of the straightener jaws 1000, 1002 by releasing the pusher bar 670. , slowly pull the wire out from between the jaws. When the wire is completely pulled out from the jaw, the straightening process is complete. However, depending on the degree to which straightening is required, the straightening work can be repeated as many times as necessary.

To aid in understanding the wire straightener 428 shown in FIG.
002 are shown in more detail in FIG. For example, the straightener jaw 1000 includes a main support member 1003, shown in part in FIG. ing. The working head 1001 includes a portion that is fitted into a groove of a support member 1003 and fixed with a pin. The surfaces that actually come into contact with the wire during the straightening operation consist of pairs of substantially rectangular surfaces that join together to form a substantially V-shaped tooth structure. The line where the multiple pairs of surfaces join is approximately parallel to the rotational axis of the straightener. The second working head 1005 also includes a similar complementary surface. In operation, the opposing portions 1005, 1001 of the straightener form offset surfaces that exert opposing forces on the piece of wire to be straightened. When the working heads are rotated and the wire is pulled, these working heads straighten the wire while applying a helical force to the wire surface.

FIG. 42 schematically illustrates a tensile testing section 470 that grips a wire and a terminal attached thereto and tests whether the terminal is properly attached by applying force between the two. For details, see Wire Support Clamp 65
6 grips the wire and positions it in front of the tensile test working section 470 as shown in FIG. Tensile testing station 470 includes two opposing jaws 1050, 1052 that clamp the wire terminal as shown in FIG.

Each jaw 21050.1052 is preferably electrically conductive and electrically isolated from the rest of the device by an insulating member 1054.1056. The insulating member is attached by a bracket 1066 to a gripper mechanism 1058 secured to a rod portion of a pneumatic cylinder 1070. A force is applied to the terminal secured to the wire by appropriately supplying air pressure to the pneumatic cylinder 1066. If the terminals are not crimped correctly, pneumatic cylinder 1
When 070 was activated, the holding force did not work and movement was detected, indicating that the terminal was not installed correctly.

Signals indicative of tensile test operating parameters are sent from the sensor to controller 402, and in response, the controller provides control signals to operate the tensile test station.

Figure 43 schematically shows the wire marking station. Functionally, this station is a standard device that utilizes ink spray technology to mark individual pieces of wire. The wire to be marked is held in one wire clamp, for example wire clamp 656, and the free end of the wire is clamped in the jaws 1078, 1080 of a gripper forming part of the marking device. Marking device is gripper jaw and wire clamp 656
It includes a pneumatic cylinder 1074 that applies tension to the wire so that it is suspended without sag. In this state, a marking device 472 prints a desired identification mark on the wire piece using a spray head 1082.
Sensors included in the controller 402 send signals indicative of operating parameters to the controller 402 . The control device 402 is the marking device 4
72.

The final operation of the wire manufacturing equipment is to remove the finished wire piece from the equipment and transfer it to the electrical wiring assembly process. This operation is accomplished in the ejector 477 by utilizing a gripper having two jaws 1100, 1101 (FIG. 45) that grip the free ends of the wire pieces. Once the wire piece is clamped in the jaws 1100.1101, the wire clamp 656.858 is released and rotated outward to obtain the space necessary to remove the wire piece from the glass container. This operation is performed by activating the pneumatic cylinder to raise the tubular members 1104 and 1106 as shown in FIG.
This is achieved by placing it over the rod. Compress the spring and release the gripper. Pivot point 1 shown in Figure 44
2 mounted so that it can pivot around 114.1116
The actuator is attached to the plate 11OL1110.

The pneumatic cylinder 1120 is then actuated to release the plate 1110.
．． 11o8 is rotated about the pivot point and wire grippers 856, 558 are rotated outwardly as shown in FIG. Sensors 1118, 1120 indicate when grippers 655, 658 open. A similar sensor is used to detect when the pneumatic cylinder 1120 has reached its limit position and confirm that the clamp is in the open position shown in FIG. In this state, the actuator simply pulls the wire piece out of the container by horizontally moving the gripper jaws 1101.1100.

FIG. 46 is a detailed view of wire container 1176.

This container is attached via block 1178 to a bracket member 1175 that maintains a spacing from plate member 708. This positions container 1176 to receive the wire.

As previously mentioned, each wire support pallet 414 is sequentially indexed to each work station location, including a "spare" location.

Each working station is provided with a suitable actuator to operate the wire support pallet 414 *. However, each working part does not necessarily require all types of actuators.

Additionally, the work stations themselves are selected to perform the required wire manufacturing functions, and the functions shown are exemplary only. The working sections themselves range from essentially known devices configured to receive wire ends from the wire transport pallet 414, such as strippers, crimpers, and marking devices, to completely original features, such as the wire straightening section 428. It can be used in a wide variety of ways, up to and including devices with Changes in the organization or function of the working section do not depart from the idea of the device of the invention.

Below, remaining white

[Brief explanation of the drawing]

Fig. 1 is a configuration diagram schematically illustrating the automatic manufacturing apparatus of the present invention; Fig. 2
The figure is an exploded perspective view of the wiring assembly tool end effector;
Figure 3 is a detailed view of the wire pulling/pull device in conjunction with the end effector; Figure 4 is for aligning and securing the pin and positioning it for pick-up by the insertion gripper. Vertical sectional view of the clamping device fixed to the wire harness cedar board; Figure 5 is a vertical sectional view of the alignment means used in conjunction with the insertion gripper; Figure 6 is a plan view schematically illustrating the wire harness cedar board layout. Figure 7 schematically illustrates how the wire enters the fixed clamp on the cedar board, the fixed clamp aligns the wire, secures the pin, and positions the wire to be picked up by the insertion gripper. Elevation view; Figure 8 is an elevational view schematically illustrating how the gripper moves along its axis to feed the wire out of the tube and close at the pin shoulder; Figure 9 shows the alignment means connected to the gripper and wire connector. Elevation diagram summarized by relationship; 1st theta
The figure is an elevational view schematically illustrating how the gripper aligns with the corresponding hole in the connector and inserts the ejecting pin into the connector; Figure 11 shows the inner clamp of the assembly tool gripper gripping the wire and inserting the pin into the connector. Figure 12 is an elevation view schematically showing how the robot gripper checks pin insertion into a connector; Figure 13 is an elevation view schematically showing how the robot gripper pulls the wire through the tool; An elevational view schematically showing how wires are laid on a cedar board insulator; Figure 14 shows the second robot gripper.
Elevation view schematically illustrating wire pin insertion into the end; Figure 15 with quick change tool adapter ° ゛UNIMAT
FIG. 16 is a schematic perspective view of a robotic manufacturing device using an ε Series 6000 electric robot in conjunction with the end effector shown in FIG. 2; FIG. 16 is a top view schematically illustrating the device incorporating the present invention; FIG. FIG. 18 is a sectional view of the sprocket supporting the conveying chain; FIG. 19 is a top view of the sprocket with attached wire conveying pallet; FIG. Figure 20 is a perspective view of the wire transport pallet; Figure 21 is a perspective view of the wire transport pallet with one of the wire clamps in the protruding position; Figure 22 is a front view showing the wire transport pallet, transport chain and support tracks. Figures; Figure 23 is another front view showing the wire conveying pallet and conveying chain; Figure 24 is a top view of the apparatus shown in Figure 23; Figure 25
The figure shows the device shown in Figure 24 with the wire in its protruding state.
Top view shown with one of the clamps; Figure 26 is a top view of the horizontal translator for a wire transport pallet; Figure 27 is a front view of the horizontal translator for a wire transport pallet; Figure 28 is a wire support clamp Figure 29 is a front view of the horizontal translator; Figure 30 is a cross-sectional view of the wire support clamp and drive chain; Figure 31 is a top view showing the horizontal index bin; Figure 32 is the wire A side view of the supply section; FIG. 33 is a top view of the wire supply section and wire reversing section; FIG. 34 is a front view of the wire reversing section; FIG. 35 is a top view of the wire reversing section; FIG. 36 is a top view of the wire reversing section; Figure 37 is a top view of the wire shear; Figure 38 is a side view of the wire shear; Figure 40 is a side view of the wire straightening part; Figure 41
The figure is a perspective view of the wire straightening jaw; Figure 42 is a side view of the terminal tension test section; Figure 43 is a side view of the wire marking section; Figure 44 is a wire transport pallet including a part of the wire take-out gripper. FIG. 45 is a front view of the wire transport pallet showing wire removal; FIG. 46 is a side view of the wire container. FIG, 1 r-m FIG, 38 FIG, 41 FIG, 42 FIG 4B FIG, 44

Claims (1)

[Claims] 1. (a) A wire processing device for cutting a wire into a predetermined length and forming a required electrical terminal at the end of the wire, and means for applying identification markings to the wire; (b) A means for applying identification markings to the wire; (c) means for supplying or conveying the terminal wire from the wire processing device to the cable harness forming device; (d) the cable; - computer means for processing harness design data and supplying operation control signals to wire processing equipment and cable harness forming equipment to enable manufacturing of the desired cable harness; Flexible automatic manufacturing equipment for wire harnesses. 2. The device according to claim 1, wherein the wire processing device includes a plurality of wire supply units that supply wires of a predetermined size to be cut into a predetermined length. 3. The device according to claim 2, wherein the wire processing device includes a wire straightening section for straightening the protruding end of the cut wire piece. 4. The apparatus according to claim 3, wherein the wire processing apparatus includes a wire stripper section for removing insulation material from the straightened protruding end of the wire. 5. The apparatus according to claim 4, wherein the wire processing apparatus includes a plurality of working parts for forming predetermined electrical terminals on the ends of the wire. 6. The cable harness forming device includes: means for making the wire with a terminal face a predetermined end effector; means for inserting the wire with a terminal into the predetermined end effector; means for positioning the end effector for insertion into a first assembly point of the terminal; means for inserting a first end of the terminal wire into the first assembly point; and means for inserting the terminal wire along the predetermined cable harness layout. means for placing the terminal wire second end into the predetermined end effector; and positioning the end effector for insertion of the terminal wire second end into the intended second assembly point. 2. The apparatus of claim 1, further comprising: means for inserting the terminald wire second end into the intended second assembly point. 7. The means for positioning the end effector for inserting the terminal wire at the intended assembly point is an orthogonal robot capable of transporting the given end effector along the X, Y, and Z axes. Apparatus according to claim 6. 8. The apparatus of claim 6, wherein a given end effector is selected from a plurality of dedicated end effectors, each of which is a dedicated working end compatible with a particular style of terminal wire. .