Project Background

A domestic automobile manufacturer has over 200 industrial robots in its welding workshop for welding body frames. Due to the high temperature (welding area temperature can reach 80-120 ℃), high metal dust, frequent mechanical vibration, and other issues in the workshop, the original ordinary wire harness has experienced insulation layer aging and damage, signal transmission interruption, and other faults. On average, the wire harness needs to be replaced every 3 months, resulting in an increase in production line downtime (a single shutdown repair takes 2-4 hours) and an increase in equipment maintenance costs. In 2022, the manufacturer initiated a bidding process for wire harness suppliers, and Lianjie Technology participated in the cooperation with targeted solutions.

Product adaptation and solutions

Lianjie Technology provides customized industrial robot body wiring harness products for the project requirements, with the following core features:

1. Material selection: The insulation layer of the wire harness is made of high and low temperature resistant modified PUR material, which can withstand a temperature range of -40 ℃ to 150 ℃, and has the characteristics of resistance to metal dust wear and oil resistance; The use of high-purity oxygen free copper as the conductor helps to improve conductivity and fatigue resistance, and is suitable for long-term mechanical vibration environments.

1. Structural design: Based on the joint motion trajectory of the robot, a flexible twisted wire structure is adopted to reduce the tensile and twisting stress of the wire harness during robot rotation, and to help extend its service life; The joint area is treated with gold plating to reduce contact resistance, which helps ensure stable signal transmission and reduces welding parameter deviations caused by poor contact.

1. Compliance aspect: The product has passed the ISO9001:2015 quality management system certification and complies with the IATF16949 standard (supplementary certification) of the automotive industry, meeting the relevant requirements of automotive manufacturing for component reliability.

Project Results

After the batch of ontology harnesses was put into use in June 2022, the relevant indicators showed the following changes:

Service life: The average replacement cycle of the wiring harness has been extended from 3 months to over 24 months, and the failure rate has decreased;

Production efficiency: The downtime of the production line caused by wire harness failures has been reduced from an average of 40 hours per year to less than 2 hours, which has a positive effect on improving the overall vehicle production capacity;

Cost situation: The annual reduction in wiring harness replacement costs and downtime losses amounts to approximately 800000 yuan, with a certain investment return.