Automatization of the Cable-Routing-Process within the Automated Production of Wiring Systems

Abstract

The wiring system is one of the most important and one of the most expensive part of modern passenger vehicles. It ́s production is done manually to nearly 100% since the early years of car manufacturing. Until today it wasn ́t possible to automatize these cost-intensive step of the car production in an effective and cost efficient way. This paper shows how the routing process of the wiring harness as a part of the whole production process can be automatized with easy and cost efficient production methods. Collaborative robots and 3D-printed prototypes of cable grippers were used to treat with the complexity of the job and to finally create a sustainable and cost efficient production system. Further the routing concept has been brought to a prototypical production cell which has been tested in various routing experiments at the institute’s laboratory. Finally, a discussion of the results brings up the strengths and weaknesses of the concept and shows possible solutions.