Integrated wire harness batch production with double buffer assembly systems

Abstract

Virtually-integrated wire harness design and automated production systems and methods that achieve completely integrated data management by automatically producing scripts to dynamically propagate production commands and data to various subsystems for handling assembling necessary circuits and wire harness layout boards to produce corresponding batches of wire harnesses while script-based methods control configuring, testing, and using wire harness layout boards, and assembling, testing, reworking, and delivering wire harnesses. As derived from CAD-created specifications, the production system uses a programmable, automated wire C&C center prepares individual wire circuits. While automatic wire indexing, sorting, and delivery systems transfer circuits into, and retrieve circuits from, a transportable programmable, automated, indexed storage system equipped with an array of individual circuit tubes, and a script-controlled assembly system sends visual, aural, and other cues to help an assembler populate and configure a wire harness layout board with connector blocks and turn posts, and guides the assembler in building, testing, reworking, and delivering the corresponding batch of wire harnesses.