Air Force Research Laboratory (AFRL) Modernizes the Wire Harness Assembly Process

The current wire harness assembly process uses dated routine of printed drawings mounted on large displays. The complex instructions are also printed on a single sheet of paper, which requires interpretation of tables, symbols, and notes. This also includes written step-by-step instructions open for free interpretation and any updates require manual labor to reprint and replace existing instructions.

Sponsored by the Air Force Research Laboratory (AFRL), is the new modernized process that utilizes Augmented Reality technology. It uses these guidelines: 1. Project accurately scaled objects, 2. System cost control, 3. Input data in its native format, 4. Multiple projector harness, 5. Sequenced data presentation, 6. Configurable harness board, 7. Configuration management via customer MES, and 8. 3-D harness projection.

Using a new optical illusion process, simplifies and streamlines the instructions needed to accurately display what process needs to be followed. Being able to visually display the assembly process allows the viewer to see the step-by-step process in order for the proper procedure to achieve correct completion.

Being in the aerospace industry, Delta Sigma is able to adapt the necessary changes within these to achieve the best wire harness assembly process. Normal files can be imported into a computer plug-in tool, which can convert and organize the normal file data into projections. Being able to adapt any major type of file source like, Capital, DXF, DWG, and other Legacy data sources. The added value to using this plug-in is being able to use a single script to complete the entire wire harness project. 

By utilizing a projection approach, the projection allows for any sort of scale adjustment, by optical surface mapping, depending on the surface size being used for that particular project. Being able to adapt easily and without reprinting and replacing paper, saves both human and environmental resources. A ticketing system can be used to flag certain aspects of a project that may need a quality check to further investigate a section that may not be up to quality standards. Being able to search a title name or scan a barcode, the search process is extremely streamlined to achieve maximum time efficiency. To further this efficiency, once the searched item is found, it is automatically projected.

The testing function of the plug-in allows for the notice of when the project meets qualifications to be tested and automatically flags areas where further development may need to take place. Allowing for the system to test the functions of the wire harness means a computer standard quality must be met prior to the developer approval.

Thanks to the AFRL, this augmented reality technology is available to all harness builders.

[cta]To find out more information regarding this progressive technological advancement, call Delta Sigma at (770) 575-5100 or email any questions to info@deltasigmacompany.com.[/cta]