Discussion topics will include:

• Guided insertion of seal plugs and pinned wires
• Eliminating errors during first-end wire harness assembly
• Partial harness testing during assembly
• Rapid continuity testing
• Troubleshooting and error correction
• Full verification testing
• Test results and reporting

The most common type of wiring errors found at final electrical tests are swapped wires, typically mis-wires. Humans build harnesses by hand, and humans make mistakes. Although robotic assembly is now available for high-volume harness manufacturing, a substantial majority of harness types are still produced in volumes, which makes manual assembly the only practical solution. Unfortunately, manual assembly is prone to mis-wires often due to difficulty identifying pin locations in connectors.

Part of the presentation will focus on a new technology introduced to the industry at the show, PinMate, an optically guided insertion tool. PinMate guides operators through inserting seal plugs and wires into electrical connectors using a super-bright projector to illuminate individual target cavities. Additionally, the presentation will cover partial harness testing, the idea of testing complex harnesses in steps during the assembly process rather than just at the final test. Troubleshooting and error correction are also done, emphasizing test results and reports. Real-life usage data of the guided insertion tool will be presented as derived from an actual wire shop of a major aircraft manufacturer.

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