Method and apparatus for high density wire harness manufacture

Claim 1

A robotic system for automatically making a wire harness by acquisition and insertion of a terminated wire into an assembly point, the system comprising: an end effector comprising a bracket means and first and second bracket elements adapted to be mounted onto an industrial manipulator, said bracket means including a strut portion, said first and second bracket elements being adapted for selected movement toward and away from each other; first and second substantially symmetrical outer jaw means, each of which is slidably mounted in said strut portion for movement substantially perpendicular to the movement of said bracket means; whereby the selected movement of the bracket means positions said outer jaw means in an open wire receiving position and a closed wire guiding and pin insertion position, said outer jaw means defining therein a wire guiding channel when closed; inner means disposed within said outer jaw means for selective actuation between a first open position and a second closed wire-engaging position; said system characterized by wire tensioning and centering means having a wire passage bore therethrough operationally associated with one of the first and second bracket elements and adapted for elevational displacement with respect to the wire passage channel of the outer jaw means, such that in a first extended position the wire passage bore of the tensioning and centering tool is aligned with the wire passage channel of the outer jaws and in a second retracted position, the wire tensioning -and centering tool is eleva- s-tionally cleared from the outer jaws, and wherein the wire tensioning and centering tool is laterally movable between a first and second position to maintain an on axis alignment with the outer jaws when said jaws are in an open wire-receiving position; a wire feed system for conveying a wire from a point remote from the end effector to a selected location for acquisition by the gripper, said wire feed system comprising tube means operatively associated with the wire passage bore of the wire tensioning and centering tool, and means for generating a back air pressure in said tube means to blow the wire from the remote location to the selected location; stationary clamp means comprising a generally rectangular member which is mounted onto a formboard, said stationary clamp means including a bore therein for receiving a terminated wire therein from said tensioning and centering device and including clamp means in said rectangular member for selectively engaging and releasing said terminated wire within said bore; and at least one alignment fixture adapted to be mounted onto the formboard and defining alignment bore means therein for receiving the terminated wire portion and outer gripper jaws for the alignment of said terminated wire portion with said jaws.

Claim 17

An apparatus for the automated manufacture of a high density cable harness comprising: means for presenting a terminated wire to a selected end effector; means for loading the terminated wire into the selected end effector; means for positioning the end effector for insertion of a first end of the terminated wire into a desired first assembly point; means for inserting the first end of the terminated wire into the first assembly point; means for routing the terminated wire along a predetermined cable harness layout; means for loading a second end of the terminated wire into the selected end effector; means for positioning the end effector for insertion of the second end of the terminated wire into a desired second assembly point; and means for inserting the second end of the terminated wire into a desired second assembly point.

Claim 18

An apparatus for the automated manufacture of a high density cable harness comprising: means for presenting a terminated wire to a selected end effector; means for loading the terminated wire into the selected end effector; means for positioning the end effector for insertion of a first end of the terminated wire into a desired first assembly point; means for inserting the first end of the terminated wire into the first assembly point; means for routing the terminated wire along a predetermined cable harness layout; means for loading a second end of the terminated wire into the selected end effector; means for positioning the end effector for insertion of the second end of the terminated wire into a desired second assembly point; and means for inserting the second end of the terminated wire into a desired second assembly point.