Currently, tape winding is done manually. This method of tape winding is time consuming. Also, due to the manual nature of the process, it is difficult to maintain the output quality. Automation in this industry is not implemented yet. This makes the wire harness manufacturing process less efficient, less reliable and less economical with lower production rates.
Figure (1.) Casing Assembly 1 (2.) ISO View of Gear Mechanism
The Wire-Harness Winding Machine System addresses the inefficiencies and challenges associated with the manual winding of wire harnesses, a process critical in industries such as automotive, electronics, and aerospace. Traditional manual methods are time-consuming, labor-intensive, and prone to inconsistencies and high vibration, leading to poor quality and inefficiency. This invention automates the winding process using high-torque servo motors and a rotating disc mechanism, significantly improving productivity and product quality. The system offers precise control over tape application, reduces vibration and noise, and can operate in various modes, including manual, semi-automatic, and fully-automatic. These advancements result in enhanced stability, reduced labor costs, and improved ergonomic conditions for workers. By integrating efficient power transmission and versatile operational capabilities, the Wire-Harness Winding Machine System stands out as a robust solution that meets the growing demands of modern manufacturing while ensuring consistent and high-quality wire harness production. This innovation not only boosts economic viability but also contributes positively to worker safety and overall production efficiency.
- The current invention uses an unwinding cam to pull out a free length of the tape and a rotating disk to wrap it over the wire harness.
- Two high torque servo motors handle both the mechanisms individually, with good efficiency. In comparison to manual tape winding, the invention increases the taping speed. This reduces the time required for taping.
- It also prevents overlapping of tape and manual contact with the adhesive surface of the tape. This leads to more effective taping, improved utilization of tape length and reduces the loss of adhesiveness of the tape.
- Versatile Operation Modes: Can operate in hand-held, semi-automatic, and fully-automatic modes, making it adaptable to various production needs.
- Ergonomic Design: Lightweight and ergonomically designed with comfortable grips, reducing user fatigue and improving handling.
- Efficient Power Transmission: Incorporates bevel gears for high transmission efficiency and reduced noise levels.
- The current invention uses an unwinding cam to pull out a free length of the tape and a rotating disk to wrap it over the wire harness.
- Two high torque servo motors handle both the mechanisms individually, with good efficiency. In comparison to manual tape winding, the invention increases the taping speed. This reduces the time required for taping.
- It also prevents overlapping of tape and manual contact with the adhesive surface of the tape. This leads to more effective taping, improved utilization of tape length and reduces the loss of adhesiveness of the tape.
Two high-torque servo motors, a rotating disc, an unwinding cam.
- Economic Benefits: Increases production efficiency and reduces labor costs, making wire harness manufacturing more economically viable.
- Quality Improvement: Enhances the quality and consistency of wire harnesses, crucial for industries that demand high reliability.
- Worker Safety and Ergonomics: Reduces the physical strain on workers by minimizing vibration and thrust impact, creating a safer and more comfortable working environment
Automotive, Electronics, Aerospace, Electrical Manufacturing
- Automotive Industry: For the manufacturing of wire harnesses used in vehicles, particularly electric vehicles which require stringent quality control.
- Electronics Industry: In the production of electronic devices that require precise and reliable wiring solutions.
- Aerospace Industry: For wiring systems in aircraft that need to withstand various environmental conditions.
- Electrical Manufacturing: For creating wiring systems in various electrical appliances and industrial equipment
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