Patent Publication Number: US-8996347-B2

Title: Digital wire harness assembly system

Description:
CROSS REFERENCES TO RELATED APPLICATIONS 
     This application claims priority benefit of a U.S. Provisional Application Ser. No. 61/070,510 filed in the United States Patent and Trademark Office on Mar. 24, 2008, and entitled “DIGITAL WIRE HARNESS ASSEMBLY SYSTEM”. 
    
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
     Not Applicable 
     REFERENCE TO APPENDIX 
     Not Applicable 
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates to wire harnesses, and more particularly to a system for assembling wire harnesses using a transparent peg board with a rear mounted visual display system. 
     SUMMARY OF THE INVENTION 
     A transparent peg board is mounted in front of a display system such as an LCD or plasma display. The display is driven by a proprietary computer program running on computer. A plurality of round dots are illuminated on the display that align with pre-determined peg holes thus indicating to an operator where various pegs should be mounted. After the pegs have been installed the wire runs are displayed one by one as the operator lays in the wire runs in the appropriate locations. Visual notes with instructions and or videos are displayed on the LCD or plasma display to assist the operator. Finally wire ties and connectors may be assembled to the harness. There is also a Quality Control mode of the program so that a QC inspector may come onto the job and inspect the ‘as built’ harness on the pegboard before it is removed. 
     The advantages and features discussed above and other advantages and features will become apparent from the detailed description of the best mode for carrying out the invention that follows. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention. 
         FIG. 1  is a perspective view of the digital wire harness system; 
         FIG. 2  is a series of screen shots of the application software user interface; 
         FIG. 3  is a schematic of the toolbar as displayed on the digital wire harness system; 
         FIG. 4  is a schematic of an instruction display on the digital wire harness system; 
         FIG. 5  is schematic of the pegboard holes being calibrated with the peg light circles on the image display; 
         FIG. 6  is a perspective view of the pegs being inserted into the pegboard; 
         FIG. 7  is a schematic of a color display illuminating a wire harness build plan; 
         FIG. 8  is a schematic showing various assembly information for operator guidance; 
         FIG. 9  is a schematic showing graphical representation of connector types and locations; 
         FIG. 10  is an perspective view of the digital wire harness system and computer; and 
         FIG. 11  is an elevation view of the pegboard, image display and protective film assembly. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENT 
     Referring now to  FIG. 1 , a digital wire harness assembly system  10  is shown. A transparent pegboard  12  is mounted on a digital display  14 . Because the pegboard  12  is optically transparent, any images (as described below) displayed by the digital display  14  are easily viewed by the operator (not shown). For example the toolbar  16 , which is an image being displayed by the digital display  14  which is beneath the pegboard  12  in this view, is easily seen in the upper left hand corner of the pegboard  12 . The digital display  14  is simply ‘mirroring’ the monitor display of a local personal computer (PC) running a proprietary software program. The operator can change the location of the toolbar  16  in several ways. One is by walking over to the PC and using conventional techniques drag the toolbar  16  on his desktop display to a new location. The digital display  14  mirrors the desktop display (not shown). 
     The pegboard  12  has a plurality of pegholes  18  drilled into its surface. The pegholes  18  are designed to receive a variety of pegs  20 . The pegholes  18  are illuminated or backlit with a green circle  22  of light emanating from the digital display  14 . Such light is coming from the digital display  14  as commanded by the PC. During an initialization process controlled by the operator and PC, the display  14  was registered or aligned with the pegholes  18  so that the green circles  22  of light were all aligned with their respective pegholes  18 . Once the on-center distance between pegholes  18  is selected on the PC at initialization, and the pegboard  12  is registered with the display  14 , the PC software generates an illumination pattern of where to display the green circles  22  of light so that they illuminate exactly behind the pegholes  18  which are to be populated with pegs  20  by the operator in the assembly process. 
     Pegs  20  are inserted into the peghole  18  locations illuminated by the green circles  22 . The display  14  also illuminates the various wire runs  24 , cable ties  26 , and a variety of connectors  28 . Not only is the shape of the particular connector  28  shown, but a text description  30  is displayed in a location next to the connector  28 . The connector  28  shape and text description  30  assist the operator in making sure the right connector  28  is assembled in that particular location. This is a great aid in eliminating costly operator errors. 
     As stated above the wire runs  24  are similarly illuminated by the display  14 . In  FIG. 1  all of the wire runs  24  are being illuminated at once, but in the build mode they are illuminated one at a time as the operator builds the harness  32 . In the build mode, only after a wire run  24  has been installed does the program move forward and display the next wire run  24 . Wire runs  24  can be color coded to indicate differing parameters such as wire size, type, gauge, insulation, and or color. 
     It should be noted that in this application the term ‘wire’ applies to any flexible conduit or tube such as optical fiber, flexible tubing, catheter, biologic tubing, nanotubing, synthetic strand materials such as Kevlar or Nylon, and any other duct, vessel or canula which can be formed in pathways. 
     Currently digital displays  14  such as plasma are approximately 30-60 inches diagonally in size but larger displays  14  have been manufactured at over 100 inches. This size limitation does not limit the size of this invention or pegboard  12  as the displays  14  can be linked together beneath a common pegboard  12 . The display software takes the entire image and breaks it up into appropriate visual segments to be displayed on each of the linked displays  14 . Special image stitching software is used to make sure that the total image displayed is true to the real dimensions required for the harness  32 . In other words the dead zones between the individual displays  14  is taken into consideration so that a wire run  24  from one display  14  to a peg  20  on the next display  14  is still dimensionally accurate. Special techniques are used to minimize the dead zones between displays  14  such as removing any bezel or frame and mounting the displays as close together as possible. Thus the pegboard  12  may be any width or length using this ‘stitching’ approach. 
     Another technology which may be used in conjunction with large pegboards  12  are the electronic billboards now beginning to populate our stadiums and highways. These billboards are large digital displays  14  that can be controlled in the same manner as in the digital wire harness assembly system  10 . Essentially the modular LED components and software to coordinate the individual displays  14  into one large visual display  14  removes size alone as a limitation. 
     Still referring to  FIG. 1 , some of the pegs  20  installed in the pegboard  12  are translucent plastic filled with a luminescent dye such that when they are backlit by the circle of light  22  on the display, the peg  20  itself lights up and can be seen from any direction in the workspace. The top of the peg  20  has a hemispherical shape so as to disperse the light  22  entering the bottom of the peg  20  shaft in all horizontal directions. 
     Referring now to  FIG. 2  a series of screen shots (SS)  34  are shown illustrating the building sequence used by the software and PC to generate a working electronic pegboard  12 . These screen shots  34  are displayed on the PC monitor during the assembly sequence. In the first screen shot, an empty pegboard  12  is shown with the peghole  18  interspacing as specified in the initialization sequence. In the second SS, the pegboard  12  area is highlighted in yellow and the wire runs  24  are laid out. In the 3 rd  SS, the peg locations  36  to be populated by pegs  20  are determined to best accommodate the wire runs  24 . In the 4 th  SS, the order of install of each of the wire runs  24  is selected. In each of the SS  34 , a list box  38  is displayed showing the operator what step of the build is being displayed. The steps  40  are clearly shown in the 3 rd  and 4 th  SS  34 . 
     It should be noted that the pegboard  12  must be transparent, not just translucent, for this invention to work. It must be completely transparent so that the operator can clearly see any of the visual information displayed by the LCD or plasma display  14  behind the pegboard  12 . The pegholes  18  can be placed on the transparent pegboard  12  in any pattern and any size depending upon the type of harness  32  and or wire sizes to be used. 
     Referring now to  FIG. 3  a toolbar  16  is shown. This tool bar  16  is visible through the transparent pegboard  12  and the pegholes  18  can be seen in a clear pattern just floating over the toolbar  16 . The toolbar  16  can be positioned anywhere on the digital display  14  and thus anywhere on the pegboard  12  by simply dragging it on the PC desktop. Another method for repositioning the toolbar  16  is to use a wireless mouse (not shown) sliding on the pegboard  12 . The wireless mouse controls the location of the cursor (also displayed on the digital display  14  in certain modes) and thus the mouse can be slid/maneuvered to position the cursor image on the digital display  14  over the toolbar  16  image on the display  14  and click/drag the toolbar  16  to a new location on the digital display  14 . 
     The toolbar  16  can be used by an operator sitting at the PC in a conventional manner or by an operator at the pegboard  12  by using a touch sensitive display screen or other technology to sense the operators pressure touches to the pegboard. It can also be activated by the wireless mouse as described above by moving an image cursor over a tool icon  40  on the toolbar  16  and clicking. 
     Referring now to  FIG. 4 , an instruction note  42  is displayed on the digital display  14  near a current work location. The wire run  24  is being displayed simultaneously with the note  42 . The note  42  is clearly visible and readable under the transparent pegboard  12 . The note  42  is being displayed to the operator in a specific location on the pegboard  12  to assist the operator in performing the assembly. Thus the operator is well focused in that his manual task in his direct view also contains written instructions to assist him. He does not have to physically go to a manual on a distant bench or desk, or even turn his attention away to look at notes on a nearby stand. Such information as connector type and location, wire color and size, special termination requirements and the like may be useful to the operator. These ‘notes’  42  can be positioned anywhere in the display  14  space and thus anywhere on the pegboard  12 . Video notes  44  (videos played by Quicktime or Windows Media Player) may also be displayed in that the LCD or plasma display  14  can play a movie in any size or location behind the pegboard  12 . Such videos may be in avi, mpeg, animated gif or other familiar video formats, and they may contain special instructions or views to assist the operator. 
     Referring now to  FIG. 5 , the digital wire harness assembly system  10  is shown with the pegholes  18  illuminated by circles of light  22 , a displayed toolbar  16  and a displayed instruction note  42 . The transparency of the pegboard  12  allows clear images to emanate from the display  14 .  FIG. 5  also shows the transparent pegboard  12  overlayed on the digital display  14  for calibration. The operator simply moves the cursor  46  until its pointer image is directly under the upper leftmost peghole  18  and clicks. He performs the same operation on the lower rightmost peghole  18 . After that the peghole  18  grid size is entered into the program such as 1″ horizontal and vertical on-center spacing of the pegholes  18 . The program automatically generates all the circles of light  22  on the display  14  that align with and illuminate the pegholes  18  on the grid. 
     Referring now to  FIG. 6 , the digital wire harness assembly system  10  is shown with only the wire run  24  pegholes  18  illuminated by circles of light  22 , and a displayed instruction note  42 . An operator is shown installing the pegs  20  into the peghole  18  pattern as illuminated by the circle of light  22  under software program control. It can be seen that some pegs  20  illuminate while the solid pegs  20  do not. This is for illustration as to the benefits of illuminating pegs  20 . 
     Referring now to  FIG. 7 , the digital wire harness assembly system  10  is shown with various wire runs  24  illuminated in a variety of colors. Each wire run  24  may have its own color. Thus an operator will lay down one specific wire on one wire run  24  or color trace from end to end, such as the color yellow. He will then lay down a physically different wire (it may or may not be the same gauge wire) on a second wire run  24  indicated by a different color such as green. Thus the uniquely colored wire runs  24  clearly show the pathway for each wire the operator is installing on the pegboard  12 . The wires will be securely held in place by the pegs  20  until cable ties  26  are installed. 
     Referring now to  FIG. 8 , the digital wire harness assembly system  10  is shown with additional display information for the operator. The digital display  14  is rendering images of connector  28  name, shape and location information. Text information  30  is also displayed describing for example location of cable ties  26 , wire type and color, and other specialized assembly instructions. 
     Referring now to  FIG. 9 , the digital wire harness assembly system  10  is shown with wire run  24 , connector  28 , and cable tie  26  information all displayed simultaneously demonstrating a full wire harness  32 , cable tie  26  and connector  28  layout. 
     Referring now to  FIG. 10  a side view of the digital wire harness assembly system  10  is shown. The display  14  is shown beneath or under the pegboard  12 . The circles of light  22  are aligned with the pegholes  18 . The display is controlled by proprietary software executing on the PC  48 . The mirror video image being sent to the display  14  is carried by any standard video signal such as S video or HD video. The display  14  can be LCD or plasma technology. 
     Referring now to  FIG. 11  a side view of the digital wire harness assembly system  10  is shown. A roll of continuous transparent film  50  may be located at one end of the pegboard  12  such that the film  50  may be pulled across and cover the pegboard  12  to protect it from scratching or to allow the operator to draw or label on such. When the film  50  needs to be changed, the old film  50  is pulled away from the continuous roll  52  allowing new film  50  to be dispensed. The film  50  can be easily punched through by special pegs  20  made for such. 
     Pegs  20  can be of various lengths and diameter to accommodate various types of harnesses  32 , wire sizes and number of wire runs  24 . 
     The grid size, shape, and pattern of the pegholes  18  in the pegboard  12  can vary to accommodate various kinds of jobs and or requirements. 
     The pegboard  12  and assembled harness  32  may be easily removed as a unit from the digital display  14  and transported to another location for further processing or assembly of the harness  32 . 
     The pegs  20  are designed to have different mechanisms for securing them to the pegboard  12 . A first method is a peg  20  having a tapered shape that frictionally engages a similarly shaped peghole  18  in the pegboard  12 . Another method is a peg  20  with bottom protruding ears designed for a twist lock bottom for mating securely with receiving grooves in the pegholes  18  of the pegboard  12 . 
     The operator can easily move his head to the side or below an installed wire run  24  to see the display information below the harness  32 . 
     A quality control (QC) inspection routine is built into the computer program to allow a QC inspector to step through the assembled harness  32  with visual display information and confirm each wire run  24  has been assembled correctly. 
     The display  14  has to be calibrated such that it is 1:1 as the harnesses  32  are being built to actual dimensions. 
     Tie wrap or cable tie  26  locations are indicated on the display  14  to assist the operator in placing them correctly. 
     A wireless mouse  54  can be used on the interactive pegboard  12 /display  14  to control the software and or program. A wireless keyboard  56  can also be placed on the pegboard  12  and used to control the software. 
     A digitized surface  58  on the pegboard  12 /display  14  allows for reverse engineering of old harnesses  32  so that the appropriate build information can be determined from an actual ‘used’ harness  32 . 
     In an alternate mode, the tool bar  16  and work instruction windows  42 ,  44  will automatically move back and forth along the length of the display  14  as the operator moves back and forth so that the displayed information  42 ,  44  is always in front of the operator. The system senses the operator&#39;s location from a wireless transmitter  60  he is wearing on his waistband, or by sensing pressure from the operator&#39;s manual work on the pegboard  12 . 
     The operator can override this ‘track’ mode through different inputs such as the wireless mouse or keypad or at the PC keyboard and mouse. The tool bar  16  and work instruction windows  42 ,  44  can be set into a fixed position on the display  14 , or operate in ‘sequence mode’ where they progress from a first work location to a subsequent work location. 
     A method for confirming that a peg  20  has been inserted and/or a wire has been placed is provided. Peg  20  insertion may be sensed from pressure in the pegboard  12  pegholes  18 , or sensing capacitive changes due to human touch as a peg  20  is inserted, or touch screen technology. Wire placement may be sensed by end to end electrical conductance along a wire run  24 , or a capacitive change along the wire run  24 . This may entail technologies or a combination of technologies such as pressure sensitive pegs, touch screen technology, and or software. In another alternative mode, the system may restrict the next image from being displayed until confirmation has been received that the previous task has been performed. 
     The fluorescent pegs  20  will be available in varying configurations, sizes and diameters. In one embodiment they are encased in a metal housing to provide maximum strength while at the same time keeping the diameter to a minimum. The metal housing may be full coverage or leave an open bottom and top for the fluorescent effect. 
     Voice recognition and audio technology will be used to communicate instructions/information or receive instructions/information. In one embodiment, the PC will support the operator with verbal commands/instructions and information. The PC will also receive and process audio acknowledgement and commands from the operator. For example, the program will not advance to the next step until it receives an acknowledgment from the operator the current manufacturing step is complete. All command normally input by keypad or mouse will be receivable by the PC with voice recognition technology. The operator may command the toolbar  16  to reposition, or request a video note or instruction note to be displayed. The operator may command the PC to advance to the next assembly instruction which will cause a new wire run to be illuminated, new notes and videos to be display. The notes can be converted into audio. The operator may wear a wireless audio headset with a microphone for communicating with the PC. 
     A variety of wireless technologies may be employed such as Bluetooth, infrared, cellular, radio frequency or any such technology that will allow for instructions/commands/information to be remotely communicated to and from the PC. 
     In another embodiment the operator may command the system  10  to display a digital ruler  62  the entire length and/or width of the display  14 . The ruler  62  will be provided in either English or Metric measure, or in any other standard units of length. Also a visual grid  64  of operator selectable dimensions such as 0.5″×0.5″ may be displayed on the digital display  14  to assist the operator in judging distance and lengths. 
     The digital wire harness pegboard  12  and display  14  are supported by a specially designed stand  64 . The stand  64  is operator adjustable in height and angle of tilt for the pegboard  12 /display  14 . The adjustment of height and tilt may be performed by mechanical, electrical or hydraulic actuators. The stand  64  also has fixed film spools at either end of the pegboard  12 , one spool for dispensing film and a second spool for receiving used film. The film advancement may be controlled by mechanical means or by an electric motor. The film advancement may be controlled through a tool icon  40  in the toolbar  16 , or via the PC, or by voice command. 
     Various wire spools  66  are attached to the stand  64  so as to be readily available to dispense all of the wire types needed for a harness  32 . A unique color LED is attached to the output of each wire spool  66  so to assist in matching the wire type with the wire run  24 . If a blue wire run  24  is displayed as the next assembly step, the operator pulls wire from the spool with the blue LED next to its output. Alternatively the LEDs may flash to indicate which spool should be used in the next step. 
     The system  10  also has operator selectable levels of transparency/brightness for the displayed tool bar  16  and instruction and video notes  42 ,  44 . These visual images can be controlled so as not to obscure the underlying wire run  24 /harness  32  images, as well as reduce unwanted brightness so as to assist in the operator&#39;s comfort by minimizing eye fatigue. 
     The foregoing description of the embodiments of the invention has been presented for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the invention be limited not by this detailed description, but rather by the claims appended hereto.