ASSEMBLY HEAD AND METHOD FOR WRAPPING A WIRE HARNESS IN AN AUTOMATED MANNER

Abstract

An assembly head is used for wrapping a wire harness in an automated manner by means of a winding module. The module has a winding head which rotates about an axis of rotation and, according to a first aspect, has a total of three pressing elements with spring-mounted rollers, which, during the taping process, press a tape against the wire harness and guide the tape in a centering manner. According to a second aspect, a belt drive having a toothed belt is provided for driving the winding head. The toothed belt engages on the circumferential side only in one portion extending over a small angular range.

Claims

1-20 (canceled)

21. An assembly head extending in a longitudinal direction, a transverse direction and a vertical direction, and being configured for automatically wrapping a transversely extending wire harness, the assembly head comprising: a winding module including: a winding head rotatably mounted about an axis of rotation that extends in the transverse direction; said winding head having an annular segment with a central winding space and a lateral insertion opening for inserting the wire harness into said winding space, wherein said annular segment is rotatably mounted about the axis of rotation; said winding head including a plurality of pressing elements secured on said annular segment; a drive for rotating said winding head; and a tape feed for feeding a tape to be pressed against the wire harness by said pressing elements during operation and during a rotation of said winding head; said plurality of pressing elements being at least three pressing elements with resiliently mounted rollers, and being configured to press the tape against the wire harness and to guide the tape in a centering manner.

22. The assembly head according to claim 21, wherein, in at least some of said pressing elements, the respective roller is held on two arms, which are connected to one another in an articulated manner at the roller and are supported by respective other ends on said annular segment.

23. The assembly head according to claim 22, wherein one of said arms is secured in a partial region of said annular segment which is at the front when viewed in the longitudinal direction and is oriented toward the insertion opening, and wherein said one arm is configured as an insertion element.

24. The assembly head according to claim 23, wherein said insertion element is one of two oppositely disposed insertion elements.

25. The assembly head according to claim 23, wherein said insertion element is movably mounted on said annular segment for adapting to different diameters of the wire harness.

26. The assembly head according to claim 21, wherein said rollers include a third roller arranged in a resilient manner in a rearward region of the winding space, remote from said insertion opening.

27. An assembly head extending in a longitudinal direction, a transverse direction and a vertical direction, and being configured for automatically wrapping a transversely extending wire harness, the assembly head comprising: a winding module with a winding head rotatably mounted about an axis of rotation extending in the transverse direction; a drive for rotating the winding head; a tape feed for feeding a tape; said winding head including an annular segment having a central winding space and a lateral insertion opening for inserting the wire harness into the winding space, and having a circumferential side, wherein the annular segment is rotatable about an axis of rotation; a plurality of adjustable pressing elements movably mounted against the wire harness and secured on said annular segment; said tape feed being configured for feeding a tape, to be pressed against the wire harness by said pressing elements during an operation and during a rotation of said winding head; said drive having a belt-shaped drive element which runs along the circumferential side of said annular segment in order to drive said annular segment, said belt-shaped drive element resting against the circumferential side only sectionally in a respective section, and said section extending over an angular range of less than 90°.

28. The assembly head according to claim 27, wherein the angular range over which said section extends lies in a range 30° to 45°.

29. The assembly head according to claim 27, wherein the angular range over which said section extends is smaller than an opening angle over which said insertion opening extends.

30. The assembly head according to claim 27, wherein said drive element rests against the circumferential side in at least two sections that are spaced apart from one another.

31. The assembly head according to claim 30, wherein at least two guide elements, which form a guide pair, are provided for said drive element of the respective section of said at least two sections.

32. The assembly head according to claim 31, which comprises a deflection element, along which the drive element is guided, arranged between said two guide pairs.

33. The assembly head according to claim 27, wherein said winding module further comprises a tape collector having a gripping unit for gripping the tape, wherein said gripping unit is movable across said insertion opening.

34. The assembly head according to claim 33, wherein said tape collector is controllable to set a tape length for a winding operation.

35. The assembly head according to claim 27, wherein said winding module further includes a cutting unit for cutting through the tape, said cutting unit being pivotable and having a cutting element which is moved to an increasing extent against the tape as a result of a pivoting movement in order to carry out a cutting movement.

36. The assembly head according to claim 27, wherein said winding module is secured on a guide unit and said winding module is movable in the longitudinal direction for executing a feed movement.

37. The assembly head according to claim 27, which comprises, in addition to said winding module, at least one fixing module for fixing the wire harness, said fixing module being arranged adjacent said winding module in the transverse direction.

38. The assembly head according to claim 27, wherein said winding module is one of two winding modules, and wherein a further module is arranged between said two winding modules in the transverse direction, said further module being a clip module for positioning a clip on the wire harness.

39. The assembly head according to claim 27, which comprises at least one swivel joint, which extends along the longitudinal direction and by means of which the assembly head can be swung open in two parts.

40. A method for automated wrapping of a wire harness, the method which comprises: providing an assembly head according to claim 21; inserting the wire harness, which extends in a transverse direction relative to the assembly head, into the winding space of the assembly head and winding a tape around the wire harness.

41. The method according to claim 40, which comprises the following method steps: pulling the tape across the insertion opening by way of tape collector; inserting the wire harness into the winding space, wherein the tape comes to rest against the wire harness and the guide rollers yield against a biasing spring force; rotating the winding head about the axis of rotation to wind the tape around the wire harness; and cutting the tape off with a cutting unit of the assembly head.

Description

[0058] In the figures, parts which act in the same way are provided with the same reference signs.

[0059] As illustrated, the winding module 2 illustrated in FIGS. 1 and 2 is preferably part of an assembly head 3 illustrated in FIG. 7. In principle, the winding module 2 can also be used as the sole module. FIGS. 1 to 6 illustrate partial regions and sections of the assembly head 3, with different components being masked out in the figures to enable the structure and function of individual partial elements to be recognized and explained better. In this case, the winding module 2 is in each case illustrated in an initial position before a banding operation is carried out.

[0060] The winding module 2 as well as the assembly head 3 generally extend in a longitudinal direction 4, in a transverse direction 6 as well as in a vertical direction 8. A plurality of components and units are arranged on a supporting frame of the winding module 2 and also of the assembly head 3.

[0061] In the case of the winding module 2 illustrated in FIGS. 1 and 2, a winding head 10 is arranged at the front end, as viewed in the longitudinal direction 4, which is designed to apply banding to a wire harness 12 (cf. FIG. 4). Here, the wire harness 12 extends in the transverse direction 6.

[0062] Furthermore, the winding module 2 has a tape feed 14, which contains a tape roll 16, on which a tape 18, in particular an adhesive tape, is wound, which is used for the banding. The tape feed 14 has a plurality of guide and deflection elements for the tape 18 as well as, in addition, a tape collector 20.

[0063] The winding head 10 is rotatably arranged and can be driven by means of a drive 22 (FIG. 2).

[0064] The construction and operation of the winding head 10 for applying the banding to the wire harness 12 will be explained below with reference to FIGS. 3 and 4 as the first essential aspect. The construction and operation of the drive 22 will be explained with reference to FIGS. 5 and 6 as the second essential aspect.

[0065] As can be seen from FIGS. 3 and 4, the winding head 10 comprises an annular segment 26 mounted rotatably about an axis of rotation 24. The latter has a central open winding space 28, which is open toward an edge side, with the result that an insertion opening 30 is formed. FIGS. 3 and 4 show a view of the side of the winding head 10 in the direction of view opposite to the transverse direction 6. This side of the winding head 10 is referred to as the winding side.

[0066] FIGS. 5 and 6, in contrast, show a view of the winding head and of the drive in the direction of view of the transverse direction 6. This side of the winding head 10 is also referred to as the drive side.

[0067] A total of three pressing elements 32a,b,c, each having a roller 34, are formed on the annular segment 26. The respective pressing element 32a,b,c is in each case mounted resiliently on the annular segment 26, and therefore the rollers 34 are resiliently mounted overall.

[0068] Two of the pressing elements 32a,b are designed in the manner of articulated levers and have two arms 36, 38 which are connected to one another in an articulated manner in the region of the respective roller 34. Here, the front arm, which is oriented toward the insertion opening 30 in the longitudinal direction 4, simultaneously defines an insertion element 36. The opposite arm, which faces away from the insertion opening 30, is referred to below as the rear arm 38. The rear arms 38 of the two pressing elements 32a, 32b are secured on the annular segment 26 in a region opposite the insertion opening 30 and have at their fastening points only a small angular spacing of at most 45° and preferably of at most 30°.

[0069] In contrast, the front arms forming the insertion elements 36 are secured on the annular segment 26 adjacent to the insertion opening 30. Here, they are mounted in a manner that allows a sliding movement in order to permit length compensation. For this purpose, the insertion elements 36 each have an elongate hole 40, into which a fastening bolt 42 engages. The angular spacing of the two fastening bolts is significantly greater than the angular spacing of the fastening points of the rear arms 38 and is in the range of 60° to 100°, for example. The insertion opening 30 generally has an opening angle a. This is sufficiently large for wire harnesses 12 of different diameters to be inserted into the winding space 28. The opening angle is, for example, 40° to 60° or up to 90°.

[0070] The special design and arrangement of the pressing elements 32a,b makes it possible to insert the wire harness 12 reliably and safely. A continuous guide structure is formed. When viewed in a transverse plane perpendicular to the transverse direction 6, said structure defines, particularly in combination with the third pressing elements 32c, a continuous, gap-free boundary of a receiving space for the wire harness 12, which is open only toward the insertion opening 30. This prevents the wire harness to be inserted from being fed in incorrectly and, for example, from entering a spatial region between the rollers 34 and the annular segment 26.

[0071] The third pressing element 32c is arranged in the rear region of the winding space 28. In this case, the associated roller 34 is resiliently supported along a guide, especially a linear guide. In this case, the guide comprises a further arm 39, which extends transversely to the two pressing elements 32a,b in the form of articulated levers and, for example, in the vertical direction 8. This further arm 39 crosses (in a plane offset in the transverse direction) the pressing elements 32a,b, in particular their rear arms 38. As a result, the receiving space for the wire harness 12 is also closed toward the rear. The two opposite end regions of the further arm 39 are preferably guided in a linear guide.

[0072] In this case, the direction of movement for the resilient compensating movement of the roller 34 of this third pressing element 32c is oriented in the direction from the axis of rotation 24 to the region between the two fastening points of the rear arms 38 (or counter to the longitudinal direction 4).

[0073] FIG. 3 additionally includes the tape collector 20. In the exemplary embodiment, this is designed in the manner of a bracket which can be pivoted about a pivot axis 44 and is of approximately U-shaped design, for example. Here, the pivoting movement, in particular the size of the pivoting angle, can be set by means of an adjusting unit. A desired length of the tape 18 can thereby be set.

[0074] At its front end, the tape collector has a gripping unit 46, by means of which the tape 18 can be gripped with a clamping action.

[0075] Furthermore, FIGS. 3 and 4 show a cutting unit 48, which is mounted so as to be pivotable about a vertical axis and has a knife-like cutting element 50. To cut the tape 18, the cutting unit 48 is pivoted against the tape 18 and successively cuts through the latter, resulting in a pulling cut.

[0076] The cutting unit 48 is arranged above the insertion opening 30 when viewed in the vertical direction 8. It therefore cuts through the tape 18 above the insertion opening 30. In this position, a loose end of the tape 18 is gripped by the gripping unit 46.

[0077] Here, the operation of the winding head 10 for carrying out the banding is as follows:

[0078] After a preceding cycle, the winding head 10 is in the initial position illustrated in FIG. 3. The loose end of the tape 18 is gripped by means of the gripping unit 46. By means of a pivoting movement of the tape collector 20, the tape 18 is pulled downward, in particular counter to the vertical direction 8, with the result that—as viewed in a projection counter to the transverse direction—the tape extends across the insertion opening 30.

[0079] In the next step, the wire harness 12 is inserted into the winding space 28. During this process, the tape 18 previously pulled down is taken along and fits snugly against one side of the wire harness 12 as it is inserted into the winding space 28. The wire harness 12 is guided into the center of the winding space 28, preferably in such a way that the axis of rotation 24 coincides with the longitudinal axis of the wire harness 12. During this process, the resiliently mounted rollers 34 yield and are pressed against the wire harness 12 with the spring force. As a result of the configuration of the three resiliently mounted rollers, the wire harness is therefore held overall in a centering manner within the winding space 28. Here, the rollers 34 touch the tape 18 and press it against the circumferential surface of the wire harness 12. After the wire harness 12 has been inserted into the winding space 28, the tape 18 is cut off by means of the cutting unit 50. Subsequently, the entire winding head 10 is rotated, with the result that the tape is successively laid around the wire harness by means of the rollers 34. The tape 18 is wound several times around the wire harness 12. After completion of the winding process, the wire harness 12 is moved out of the winding space 28 again. The insertion and removal of the wire harness 12 is preferably accomplished by means of a movement of the winding head 10, preferably together with the entire winding module 2, which is movable in and counter to the longitudinal direction 4. During this process, the wire harness 12 is preferably fixed in position.

[0080] The winding module 2 is also particularly suitable for securing further elements, such as a clip 52 (cf. FIG. 7, for example), on the wire harness 12. Clips 52 of this type typically have fastening legs which extend along the wire harness 12 and rest on it. In the region of such a fastening leg, the wire harness 12 is therefore typically no longer circular but noncircular. In such applications too, reliable banding is ensured by the resiliently mounted rollers 34.

[0081] In the exemplary embodiment, the drive 22 that can be seen in FIGS. 5 and 6 is designed as a toothed belt drive. The annular segment 26 has a toothed circumferential side 54, which is necessarily interrupted in the region of the insertion opening 30. The annular segment 26 is therefore designed in the manner of a toothed belt pulley or has at least one such toothed belt pulley.

[0082] The drive 22, which is constructed in the manner of a belt drive unit, has a drive pulley, a plurality of guide elements constructed in the form of guide pulleys 56 and a deflection element constructed in the form of a deflection pulley 58. Two adjacent guide pulleys 56 each define a guide pair, and the deflection pulley 58 is arranged between the two guide pairs. A belt-shaped drive element, which is designed as a toothed belt 60 in the exemplary embodiment, is guided around these pulleys.

[0083] Here, a respective guide pair defines a section 62, in the region of which the toothed belt 60 rests against the annular segment 26 and engages in the toothed circumferential side 54. In this case, the respective section 62 extends over a comparatively small angular range β, which in the exemplary embodiment is approximately 45°.

[0084] In this case, the angular ranges α, β as well as other angular ranges indicated here are each defined by an angular range with reference to the axis of rotation 24. In the case of the section 62, the angular range β is defined by the angular spacing between the two axes of rotation of the guide pulleys 56. Here, the angular range β is, in particular, smaller, for example by 5° to 10°, than the opening angle α of the insertion opening 30.

[0085] The comparatively short engagement length of the toothed belt 60 in a respective section 62 ensures that the teeth of the toothed belt 60 and those of the toothed circumferential side 54 engage in one another reliably and without offset. This ensures reliable, trouble-free operation.

[0086] During the winding process, the annular segment 26 rotates several times about the axis of rotation 24. Owing to the insertion opening 30 and the associated noncircular circumferential side of the annular segment 26, this would lead to an offset occurring in the case of large sections 62 and the teeth of the toothed belt 60 would no longer reliably engage in the toothing of the annular segment 26 and would therefore possibly run tooth to tooth.

[0087] With reference to FIG. 5, it can also be seen that the winding module 2 is secured on a guide unit 64, by means of which a feed movement in and counter to the longitudinal direction 4 is made possible. The entire winding module 4 can therefore be adjusted relative to the support frame. For this purpose, a corresponding feed drive and, for example, a suitable linear guide, especially a guide rail, are provided.

[0088] A further aspect can be seen from FIG. 2:

[0089] The winding module 2 itself can be swung open in two parts in a lower region by means of a swivel joint 66 about a pivot axis extending in the longitudinal direction 4. As a result, improved access is made possible, for example, either for replacing the tape roll 16 or else for maintenance purposes.

[0090] FIG. 7 illustrates an illustrative embodiment of the assembly head 3 in which the winding module 2 described above is accommodated. In the case of this assembly head 3, a plurality of modules is arranged directly adjacent to one another in the transverse direction 6. In the exemplary embodiment, two winding modules 2 are arranged on both sides of a central center module. In this case, this center module is designed as a clip module 70, which is designed to position the clip 52 on the wire harness 12. In addition to the two winding modules 2, a respective fixing module 72, by means of which the wire harness 12 is fixed, is arranged on the outside in each case. The fixing module 72 is used to hold the wire harness 12 by clamping, and for this purpose has suitable fixing elements, for example in the form of adjustable clamping arms.

[0091] In a preferred embodiment, the winding module 2 is used, together with at least one fixing module 72, preferably with fixing modules 72 arranged in each case on both sides of the winding module 2, as a common assembly head 3 without further modules, in particular without a clip module 70, for example in order to provide a (loose) wire bundle with banding.

[0092] The entire assembly head 3 is preferably secured on an adjusting device which can move the assembly head 3 in space. This is, in particular, a robot. Here, the entire process cycle for banding and securing the clip 54 is, for example, as follows:

[0093] The assembly head 3 is moved to a supply station, at which clips 52 are supplied individually. A respective clip 54 is gripped by means of the clip module 70. The assembly head 3 moves to an assembly position at which the wire harness 12 is supplied. Here, the assembly head 3 is oriented in such a way that its transverse direction 6 coincides with the longitudinal direction of the wire harness 12. The clip 54 is positioned by means of the clip module 70 at a desired position (angular position) on the circumferential side of the wire harness 12 and held in this position. For this purpose, the clip module 70 has a gripper 74 of corresponding design, which is of very narrow construction. Its width in the transverse direction 6 is, for example, only in the range between 10 and 30 mm. The winding modules 2 are arranged directly adjacent to this very narrow clip module 70. The two winding heads 10 are fed in in the longitudinal direction 4, with the result that they are guided over the wire harness 12 and the latter lies in the respective winding space 28. Banding then takes place. By means of the banding, the two fastening legs of the clip 52 are wrapped together with the wire harness 12, and thus the clip 52 is secured on the wire harness 12. The gripper 74 then releases the (now fixed) clip 52, and the clip module 70 as well as the winding modules 2 are returned to the initial position counter to the longitudinal direction 4. A new cycle begins.

LIST OF REFERENCE SIGNS

[0094] 2 winding module [0095] 3 assembly head [0096] 4 longitudinal direction [0097] 6 transverse direction [0098] 8 vertical direction [0099] 10 winding head [0100] 12 wire harness [0101] 14 tape feed [0102] 16 tape roll [0103] 18 tape [0104] 20 tape collector [0105] 22 drive [0106] 24 axis of rotation [0107] 26 annular segment [0108] 28 winding space [0109] 30 insertion opening [0110] 32a,b,c pressing element [0111] 34 rollers [0112] 36 insertion element / front arm [0113] 38 rear arm [0114] 39 further arm [0115] 40 elongate hole [0116] 42 fastening bolts [0117] 44 pivot axis [0118] 46 gripping unit [0119] 48 cutting unit [0120] 50 cutting element [0121] 52 clip [0122] 54 circumferential side [0123] 56 guide pulley [0124] 58 deflection pulley [0125] 60 toothed belt [0126] 62 section [0127] 64 guide unit [0128] 66 swivel joint [0129] 70 clip module [0130] 72 fixing module [0131] 74 gripper [0132] α a opening angle [0133] β angular range