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Method and Process for Verification of Brakeline Hose Routing Disclosure Number: IPCOM000114819D
Publication Date: 2005-Mar-29
Document File: 2 page(s) / 353K

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The Prior Art Database

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Method and Process for Verification of Brakeline Hose Routing

Different model vehicles from the same vehicle platform can have variations in ride height (sedan FWD, sedan AWD, wagon AWD), while sharing many common chassis components. A common brake jounce line was used for three such vehicles assembled on the same line. It was found during a pre-production build phase that the flexible brake hose with a two point connection could be mis-routed in the final assembly position. Changes to the product to eliminate the assembly concern would add complexity and cost to the overall system, as well as introducing alternate sources of error. In addition, necessary Design Verification testing for a design change would not meet program timing.

A method and system to ensure detection of incorrect assembly of the brakeline was developed and implemented. The system requires no functional modification to the product, can accommodate the current product complexity, and works on the moving assembly line. The system is "fail safe", ensuring only correctly assembled product are OK'd to ship. It is integrated to the plant's Error Proofing QLS system, and stores data by VIN for all vehicles inspected.


A machine vision system was implemented to inspect the brake jounce line on the driver and passenger side. The vehicle enters the station and trips a part present proximity sensor. LED spot lights are strobed to backlight the wheel well, and cameras on either side of the vehicle image the wheel well to inspect for routing of the hose. The vehicle passes a reader which identifies the vehicle by ID to the Error Proofing Station. All of this occurs on a moving line with the vehicle in a clam shell carrier.

Figure 1. The machine vision station and product being inspected

The wheel well is a noisy visual image for the machine vision system to analyze. The brakeline is a flexible rubber hose that can assume an infinite number of positions. The system uses the "rub rings" on the rubber hose (implemented for wear against the wheel turning) as key features to locate the position and routing of the brakeline. The rub rings are two sets of five washers molded onto the hose at the supplier. The brake hose supplier removed the black pigmentation from the rub rings. The resultant brake hose appears no different to the vehicle customer, bu...