U.S. Army Manufacturing Methods and Technology Program Covering Application of Automated Manufacturing Process to Methods for Affixing Electrical Connectors to Cables (Project No. 3091)

摘要

As a result of this program, the following conclusions were reached: The concept for the mechanizes assembly of cables and harnesses has been shown to be achievable and practical. All of the basic conceptual factors determined in the previous contractual work (reference contract No. DAAH01-74-C-1069) have been verified and demonstrated in practice. Acceptable harness assemblies were made using precut and preterminated wires fabricated prior to the assembly procedure and in accordance with a wire list. Costly custom fabrication during the assembly process is not necessary and can be incorporated into the preliminary wire preparation phase using previously demonstrated equipment. Many of the twisted pairs and shielded wires currently specified in harnesses were found to be unnecessary to the design function of the unit. With careful planning and design, a larger percentage of the harness wires can become automation-compatible and increase the potential savings through use of the mechanized facility. Additional development effort could substantially advance the capability and flexibility of the harness assembly equipment toward a production type facility. The harness designs and components must be simplified and standardized so the designer, the components, and the equipment become a more effective functioning loop that creates optimum designs in shorter turnaround times and at lower cost. The cost studies have shown that more than a 75 percent savings can be achieved with nominal care in design and use of mechanized harness assembly facilities.