Wiring Looms

[zedbiker]

We are developing an automated machine used in the field of scientific research. We are just about ready for production (3 or 4 a month).

I have been given the task of finding a quick and easy way of designing a jig to produce the wiring looms for the machine.
Has anybody got any cheap, accurate (length of wires), easy to use ideas for producing looms. The two main looms are to a 25way and 37 way d-connector. We would like to be able to cut the wires to length, label and terminate while fixed to the jig.
Does anybody know of any good ways of doing this? How is it done in industry? We might very well go to the plywood and nails idea but just wondered if anybody had a better idea. Is there something on the market that you can buy to do such a thing which doesn't cost the earth?

Look forward to your replies.
Ian

 

[VEBill]

The systems that were used here were essentially 'plywood and nail', but with the mating connectors and a PC-based system to guide the worker while confirming the connections. The system even allowed the worker to find the next wire by simply touching it (completing the circuit). I just went looking for the brand name of the system, but the systems must be in storage or something.

Another option is to design the system to use snap-on connectors and ribbon cables.

Another option is to farm out the cable work to minimize your own NRE.

 

[zedbiker]

Thanks for that. The idea of the worker being able to touch the wire to confirm connection and PC based system sounds ideal.
If you do come across the brand name of the system I would be grateful.
Unfortunately ribbon cables are not appropriate for this system.
If we do get to the stage where we need to produce lots of machines then we will have to farm out the looms but we prefer to keep them in house for quality control.

Thanks again for the ideas

 

[VEBill]

Might have been this one, or something similar...

Link:

https://www.csts.com/ucont.htm

 

[VEBill]

Oh, note the following...

"...[card] plugs into an empty ISA slot..."

Save your old PCs !! ;-)

 

[itsmoked]

Nails on boards IS the standard. Low tech, easy to change. Non confusing. It works!

Also you can paint or print or draw instructions all over it with arrows and notes. (where each tie wrap goes, etc.)

For just ribbon cables you can often use just a large "D" drawing with instructions. Sometimes if the cable is longer than a "D" drawing you draw the cables with gaps in the middle and then provide the recipe like "place two pieces of tape on a bench 51 inches apart"

 

[VEBill]

The advantage of the PC-based systems is that the cable is functionally tested (for correct point-to-point) as it is being made (essentially zero miswires).

Also, the feature that allows the operator to find a wire by simply touching it (with their finger) obviously speeds up the assembly process.

There's obviously a trade-off in terms of how many cable sets you plan to build...