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July, 2016
Smart Assembly and Test in Cable and Harness Manufacturing
By Margaret Bishop, Ph.D., CAMI Research, Inc. S
ince quality and productivity are the main priorities in cable and harness manufacturing,
test engineers typically turn to PC- based cable and harness testers. PC- based systems are operated by an autonomous (rather than embedded) computer and offer superior flexibili- ty when developing a smart test and assembly line, in part because such systems have many easy-to-use, pro- grammable functions. Having a wide range of input
and output controls with which to customize and automate assembly and test, these testers allow key peripherals to be incorporated into the test setup, for example, lock and release latches, diverter gates, auto- matic molding equipment, presence sensors, light signals, remote control, barcode readers, and label printers. For integration with other test equip- ment, PC-based systems often in - clude API and LabView interfaces.
PC-Based Test Systems Being independent of embedded
computer architecture, PC-based tester hardware is more robust, easi- er to upgrade, and has a longer life- cycle. Consistent with mixed-model manufacturing requirements, com- panies that require a flexible, versa- tile test system, with dynamic graph- ic-rich GUI, archival data-logging, and ISO9000 quality documentation
Onanon on-bench PC-based test system. Versatile features enable test
automation. For example, software allows simple scripting and macros to be written that can test switch posi- tions in a harness sequentially. Similarly, harness clamps can be automatically released if a given test
data-logging improve traceability and productivity and deliver an error-proof test process. The systems are able to scan badges for operator login, and provide work orders for automatic tester setup. Furukawa has a smart test line
typically benefit from PC-based sys- tems. Smart assembly and test incor- porates efficient use of a tester’s inputs and outputs to increase quali- ty and productivity.
is passed, or a control warning light activated if a test is failed. At test con- clusion, an ISO9001 level of report is output together with a label. Barcode tracking and archival
of over 30 stations, each powered by a PC-based tester. The user interface is comprised of a graphical user interface and a harness board fitted with continuity-test blocks, a lock and release latch, presence-test devices, a static barcode scanner, and test pushbutton. The test instrument itself remains “hidden” beneath the harness board and checks for connec- tion signals from the presence-test devices. Continuity testing proceeds automatically once these devices detect simultaneous attachment and signal proper installation of the har- ness under test. The lock and release latch receives a release signal from the tester only if the test yields a “pass” result. On the other hand, Onanon’s
smart assembly and test line uses on-bench PC-based testers fitted with connector assembly fixtures and guided assembly software. In a sec- ond-side pinning guided assembly, when probing a wire that is to be con- nected, the targeted pin and wire color are highlighted both graphical- ly and with speech (e.g. “red wire to pin J”). Once a connection is made, audible feedback confirms a proper connection or warns of an error. Speech and light-guided assem-
bly instructions increase product quality and throughput by reducing operator fatigue, and by distilling the
Continued on page 61
JADE PRO
Ultra flexible, offline, multi-platform selective soldering system
FEATURES:
DC servo drives Inerted Nitrogen system Drop-Jet fluxer Manual fiducial correction system Universally adjustable tooling carrier Optional twin solder bath capability on independent Z axis
Optional side mounted auto bath changeover Optional large solder bath for dedicated single dip applications
ORISSA FUSION
High speed, inline, multi-platform, selective soldering system
FEATURES:
Available in 2, 3 and 4 station configurations Up to 457mm x 1115mm PCB handling capability* DC servo drives with encoders on X, Y and Z axis Solder wave height measurement and correction Automatic solder wire feed and level detect Process viewing camera(s) *Configuration dependent
Pillarhouse International Ltd.
www.pillarhouse.co.uk Tel: +44 (0) 1245 491333 Email:
sales@pillarhouse.co.uk Pillarhouse USA, Inc.
www.pillarhouseusa.com Tel: +1 847 593 9080 Email:
sales@pillarhouseusa.com Pillarhouse (Suzhou) Soldering Systems Co., Ltd.
www.pillarhouse.cn Tel: +86 512 6586 0460 Email:
sales@pillarhouse.cn
Pillarhouse... Expect innovation Pillarhouse INTERNA TIONAL
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