Högskolan i Skövde

As the automotive industry shifts from combustion vehicles to electric vehicles, the importance of wire harness assembly in manufacturing has increased. This project addresses the ergonomic challenges faced by workers during the wire harness assembly at the bumper station of an electric vehicle factory. The primary concern is the physical strain required to apply clips, leading to a risk of musculoskeletal disorders (MSDs) among workers.

The initial analysis involved breaking down the assembly tasks and preparing the workstation with motion capture equipment and force sensors. Participants performed the tasks, and their movements and exertions were recorded. Ergonomic evaluations using HARM, HandPak, and RULA methods highlighted significant risks, prompting the need for improvements.

Redesigning the clips to reduce physical effort was a key focus, with promising initial results. Additionally, elements of Industry 5.0 were integrated by designing a clip specifically for use with collaborative robots (cobots), aiming to enhance productivity and reduce worker discomfort.

Digital Human Modelling (DHM) tools and motion capture technology played a crucial role in evaluating the new designs and simulating different scenarios. Although challenges were encountered, such as issues with 3D printing materials, the project successfully demonstrated potential ergonomic improvements and the benefits of robotic assistance.

In conclusion, this project highlights the need for ergonomic considerations in manufacturing processes to prevent MSDs, improve worker well-being, and increase productivity. The combination of redesigned clips and robotic integration offers a pathway to safer and more efficient assembly processes in the electric vehicle industry.