Wire harness assembly system and method for assembling electrical pipe modules

Abstract

The invention relates to a wire harness assembly system and method for assembling an electrical pipe module. A harness assembly system for assembling an electrical pipe module includes a pipe assembly jig, a harness shuttle subsystem, at least one robotic manipulator, and a system controller. A method for assembling an electrical pipe module includes receiving a pipe assembly jig on a workpiece support structure from a pipe preparation area and receiving a wire harness from a wire harness preparation system for placement in the pipe assembly jig. The wire harness is positioned on an upper surface of the tool support structure between a shuttle holding the first terminating end and another shuttle holding the other terminating end. The wire harness is picked up from the upper surface of the tool support structure, the first shuttle, and the second shuttle, and placed at a predetermined location in the pipe assembly jig. This process may be repeated on additional wire harnesses until the electrical pipe module is assembled.

Description

Technical Field

[0001] The present disclosure relates generally to a harness assembly system for assembling electrical conduit modules, and more particularly to techniques for assembling electrical conduit modules. Various techniques control one or more robotic manipulators and a harness shuttle subsystem to assemble the electrical conduit module in a conduit assembly fixture. Background Art

[0002] Business practices for wire harness manufacturing have remained essentially unchanged since the 1960s. For conduit routing, individual wire harnesses are prepared, terminated into a first-end connector, formed into individual wire harnesses, terminated into a second-end connector, and assembled as bundles onto conduit supports. The conduit supports are transported to the factory and installed in a final product, such as an aircraft. This process can currently take 45 man-hours. Furthermore, the current process includes many non-value-added steps related to packaging, shipping, receiving, and unpacking. The process can also result in a large work-in-progress buffer due to scarce resources and / or long material lead times.

[0003] Electrical wiring conduits consist of numerous electrical wiring bundles that run the length of a finished product, distributing data, signals, and power throughout the product. For example, an aircraft typically has four or five conduits running the length of the aircraft. These conduits are physically separated from one another to mitigate physical threats, such as a falling engine blade or a bomb explosion.

[0004] Traditionally, conduit is assembled using the following process. Long bundles of wire harnesses are assembled, tested, coiled, packaged, and shipped to the electrical system responsibility center. A third party may assemble these bundles of wire harnesses. The electrical system responsibility center receives the bundles, unfolds them, and assembles them with other similar bundles on a longer assembly workbench. The bundles are tied and / or clamped together and attached to a spanner bar substructure. These long assemblies are then coiled onto a transport and transported to the final product assembly plant. At the final product assembly plant, these assemblies are unfolded, loaded into the final product, lifted, and installed. Final products such as aircraft can use particularly large transports to avoid the tasks of winding, unfolding, and lifting. Traditional conduit assembly is based on the final product production line.

[0005] Existing conduits, wiring harnesses, and bundles can include harnesses ranging from 24 inches to 100 feet. Current technology for assembling such harnesses in conduits requires extensive manual manipulation. For example, there is no known solution for autonomously managing harness length variability.

[0006] Therefore, those skilled in the art continue to conduct research and development work to improve the technology for autonomous preparation of wiring harnesses and the technology for autonomous transportation of wiring harnesses (autonomously prepared and / or manually handled). Summary of the Invention

[0007] Examples of harness / conductor / wire assembly systems and methods for assembling electrical conduit modules are disclosed.The following is a non-exhaustive list of examples that may or may not be claimed according to the subject matter of the present disclosure.

[0008] In one example, a wire harness assembly system for assembling electrical conduit modules includes a conduit assembly fixture, a wire harness shuttle subsystem, at least one robotic manipulator, and a system controller. The conduit assembly fixture is disposed on a top surface of a workpiece support structure. The wire harness shuttle subsystem includes a first shuttle disposed on an upper surface of a tool support structure and a second shuttle disposed on the upper surface. The at least one robotic manipulator is disposed on the upper surface of the tool support structure. The system controller is in operative communication with the wire harness shuttle subsystem and the at least one robotic manipulator to control placement of a wire harness from the first and second shuttles to the conduit assembly fixture.

[0009] In one example, a method for assembling an electrical conduit module includes: (1) receiving a conduit assembly fixture from a conduit preparation area on a workpiece support structure, the workpiece support structure being adjacent to a tool support structure; (2) receiving a wire harness from a wire harness preparation system to be placed in the conduit assembly fixture, the wire harness including a first termination end and a second termination end; (3) positioning the wire harness on an upper surface of the tool support structure between a first shuttle holding the first termination end and a second shuttle holding the second termination end; (4) picking up the wire harness having the first termination end and the second termination end from the upper surface of the tool support structure, the first shuttle, and the second shuttle; and (5) placing the wire harness at a predetermined position in the conduit assembly fixture.

[0010] In another example, a method for assembling an electrical conduit module includes: (1) receiving a conduit assembly fixture from a conduit preparation area on a workpiece support structure, the workpiece support structure being adjacent to a tool support structure; (2) receiving a wire harness from a harness preparation system to be placed in the conduit assembly fixture, the wire harness including a first termination end and a second termination end; (3) positioning the wire harness on an upper surface of the tool support structure between a first shuttle holding the first termination end and a second shuttle holding the second termination end; (4) picking up the wire harness having the first termination end and the second termination end from the upper surface of the tool support structure, the first shuttle, and the second shuttle; (5) placing the wire harness at a predetermined position in the conduit assembly fixture; (6) repeating the receiving, positioning, picking up, and placing of the wire harness for the next wire harness until all wire harnesses designated for autonomous placement in the conduit assembly fixture are placed; and (7) transferring the conduit assembly fixture to a post-wire harness assembly area for performing a manual assembly process on the conduit assembly fixture to prepare the electrical conduit module for installation in a final product.

[0011] Other examples of the disclosed harness assembly system and method for assembling electrical conduit modules will become apparent from the following detailed description, the accompanying drawings, and the appended claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 is a functional block diagram of an example of a manufacturing system for assembling wire harnesses, conduit assembly fixtures, and electrical conduit modules;

[0013] Figure 2 is a functional block diagram of an example of a wire harness assembly system for assembling an electrical conduit module;

[0014] Figure 3 is a front view of an example of a wiring harness;

[0015] Figure 4 It is used for transport Figure 3 A front perspective view of an example of a wire harness carrier of a wire harness;

[0016] Figure 5 yes Figure 2 A top functional diagram of an example of a pipe assembly fixture of a wire harness assembly system;

[0017] Figure 6 is a top functional diagram of another example of a wire harness assembly system for assembling an electrical conduit module;

[0018] Figure 7 is used for Figure 6 A functional block diagram of an example of a harness shuttle subsystem of a harness assembly system;

[0019] Figure 8A It shows Figure 6 A top functional diagram of a portion of a wiring harness assembly system;

[0020] Figure 8B It shows Figure 6 A top functional diagram of another portion of the wiring harness assembly system;

[0021] Figure 9 It shows Figure 6 a perspective view of an example of a portion of a harness shuttle subsystem in a harness assembly system;

[0022] Figure 10 It shows Figure 6 A perspective view of an example of an insertion robot manipulator in a wire harness assembly system;

[0023] Figure 11 It shows Figure 6 A perspective view of an example of a transfer robot manipulator in a wire harness assembly system;

[0024] Figure 12 It shows Figure 6 A perspective view of an example of an auxiliary operation robot manipulator in a wire harness assembly system;

[0025] Figure 13 It shows Figure 6 A perspective view of another example of an insertion robot manipulator in a wire harness assembly system;

[0026] Figure 14 is a flow chart of an example of a method for assembling an electrical conduit module;

[0027] Figure 15 It is a combination Figure 14 A flow chart of another example of a method for assembling an electrical conduit module;

[0028] Figure 16 is Figure 14 A flowchart of an example of a method for receiving a pipe assembly fixture;

[0029] Figure 17 is Figure 14 A flowchart of another example of a method for receiving a pipe assembly fixture;

[0030] Figure 18 is Figure 14 A flowchart of an example of a method for receiving a wire harness;

[0031] Figure 19 yes Figure 18 A flowchart of an example of picking up a coil of a wire harness;

[0032] Figure 20 yes Figure 18 A flowchart of an example of placement of a coil, a first terminating end, and a second terminating end;

[0033] Figure 21 is used for Figure 12 A front perspective view of an example of an end effector of an assisted manipulation robotic manipulator;

[0034] Figure 22 is Figure 14 A flowchart of an example of a method for positioning a wire harness;

[0035] Figure 23 yes Figure 22 A flowchart of an example of movement of the first shuttle;

[0036] Figure 24 yes Figure 22 a flowchart of an example of movement of the second shuttle;

[0037] Figure 25 is Figure 14A flowchart of an example of a method for picking up a wire harness;

[0038] Figure 26 is Figure 14 A flowchart of an example of a method for placement of a harness;

[0039] Figure 27 is Figure 14 A flowchart of another example of a method for picking and placing a wire harness;

[0040] Figure 28 It is a combination Figure 27 in Figure 14 A flowchart of yet another example of picking and placing a wire harness in a method;

[0041] Figure 29 It is a combination Figure 27 And the 28th one in the picture Figure 14 A flowchart of yet another example of picking and placing a wire harness in a method;

[0042] Figure 30 is a flow chart of another example of a method for assembling an electrical conduit module;

[0043] Figure 31 is Figure 30 A flowchart of an example of a method for receiving a pipe assembly fixture;

[0044] Figure 32 is Figure 30 A flowchart of an example of a method for receiving a wire harness;

[0045] Figure 33 is Figure 30 A flowchart of an example of a method for positioning a wire harness;

[0046] Figure 34 is Figure 30 A flowchart of an example of a method for picking up a wire harness;

[0047] Figure 35 is Figure 30 A flowchart of an example of a method for placement of a harness;

[0048] Figure 36 is Figure 30 A flowchart of another example of a method for picking and placing a wire harness;

[0049] Figure 37 is a block diagram of an aircraft production and service method that implements one or more examples of the method disclosed herein for assembling an electrical conduit module; and

[0050] Figure 38is a schematic diagram of an aircraft incorporating a ducting architecture assembled using one or more examples of the harness assembly systems and methods disclosed herein for assembling electrical ducting modules. DETAILED DESCRIPTION

[0051] The various examples of the harness assembly system 100 and methods 1400, 1500, 3000 disclosed herein for assembling electrical conduit / channel / trunking / raceway modules provide techniques for autonomously manufacturing conduits by routing individual wire harnesses 300 through the conduit assembly fixture 202 using a robotic manipulator 218 and inserting the first and second termination ends 306, 308 into the electrical connectors 512. The conduit assembly fixture 202 arrives at the harness assembly system 100 from the conduit preparation area 106 and is fully prepared to begin automated routing of the wire harnesses 300 from the harness preparation system 102 (see, e.g., FIG. 2 ). Figures 1 to 3 ). For example, unshielded single conductors, shielded cables, and unjacketed cables can be prepared / prepared in the harness preparation system 102 and loaded onto overhead conveyor carriers within the harness delivery system 104 for delivery to the harness assembly system 100. The rear harness assembly area 108 handles manual cable installation, trimming of the harness 300, and quality inspection. For example, quad coaxial cables, fiber optic cables, and coaxial cables can be prepared in the harness preparation system 102 and manually routed in the rear harness assembly area 108. The output from the rear harness assembly area 108 is a complete electrical conduit module ready for installation into a final product (e.g., an aircraft).

[0052] The spanner bar supply line leading to the pipeline preparation area 106 creates a spanner bar kit for each pipeline module construction. The kit includes spanner bars for the pipeline module construction, wherein the required flyaway and temporary (i.e., non-flyaway) layout settings are installed. The connector supply line leading to the pipeline preparation area 106 creates a connector kit for each pipeline module construction. The kit includes connectors 512 and related components for the pipeline module construction. As needed, the kit includes both modular connectors and standard connectors.

[0053] The harness preparation system 102 prepares each cable to its final length, with both ends terminated using primarily in-house manufacturing and loaded onto an overhead transport carrier. Specific in-house manufacturing methods are used for each type of harness 300. Unshielded single conductors are prepared by cutting and crimping. Shielded and bare cables are prepared by cutting and installing modular inserts. The harness preparation system 102 also prepares each cable to its final length, with both ends terminated using a dedicated mobile line and loaded onto an overhead transport carrier. Quadcoax, coaxial, fiber optic, and specialty cables are prepared using cutting and modular inserts or crimping devices. The harness delivery system 104 includes an overhead conveyor system to transport the harnesses 300 from the harness preparation system 102 to the harness assembly system 100. The harness delivery system 104 also transports the harnesses 300 to the post-harness assembly area 108. The harness delivery system 104 provides conveying, sorting, and buffering, with redundant paths to accommodate unexpected downtime in upstream and downstream work cells. The conduit preparation area 106 assembles the conduit assembly fixtures 202. Flyaway and temporary (ie, non-flyaway) hardware are installed to prepare the harness assembly system 100.

[0054] The wire harness assembly system 100 includes a tending robotic manipulator 614 and a wire harness shuttle subsystem 208 to retrieve the wire harness from the wire harness delivery system 104 and position the wire harness 300 next to the conduit assembly fixture 202. The wire harness assembly system 100 enables robotic pick-up and placement of the wire harness 300 into the conduit assembly fixture 202 and robotic insertion of the first end 306 and the second end 308 of the wire harness 300 into the connectors 512, 518. For unshielded single conductors, the crimped ends are inserted into the connectors 512, 518 (e.g., modular connectors or standard connectors). For shielded and unjacketed cables, modular connector inserts are installed into the retainers.

[0055] The rear harness assembly area 108 includes the removal of temporary (i.e., non-fly-away) hardware from the conduit assembly fixture 202. The rear harness assembly area 108 can also be used for the manual routing and installation of cables (such as quad coaxial cables, fiber optic cables, coaxial cables, and specialty cables). Cable trimming, bundling, securing, and stowing can also be completed at the rear harness assembly area 108. Final assembly and closure of the connectors 512 can also be completed at the rear harness assembly area 108. The rear harness assembly area 108 is used for various final assembly tasks and testing, including continuity testing and quality inspection.

[0056] Pipe assembly fixture 202 (see Figure 5) includes one or more longitudinal routing channels 516 along which multiple groups of wire harnesses 300 are routed. The longitudinal routing channels 516 typically accommodate only one split code of wire harnesses 300. The conduit assembly fixture 202 includes a non-flying wire harness routing support 514 for each longitudinal routing channel 516 that aligns with the final product frame or structural element to which the electrical conduit module will be mounted. These non-flying wire harness routing supports 514 support the wire harnesses 300 extending along a given longitudinal routing channel 516 during both automated and manual routing processes.

[0057] The conduit assembly fixture 202 may also include non-flyaway harness routing supports 522 for supporting the wiring harnesses 300 that branch out from the longitudinal routing channels 516 to the longitudinal side panels 504 of the conduit assembly fixture 202. These harness routing supports 522 are used to support the wiring harnesses 300 that branch out from the longitudinal routing channels 516 and extend to the connectors 518 or printed circuit board 520 mounted on the longitudinal side panels 504 during assembly of the electrical conduit module, thereby forming wiring breakouts. Note that the wiring harnesses 300 may not extend between opposing long sides of the conduit assembly fixture 202 within a single bay. If the longitudinal routing channels 516 do not have any breakouts within a given bay, then that longitudinal routing channel 516 does not include harness routing supports 522 for breakouts. Additional harness routing supports 514 may be added to the conduit assembly fixture 202 for manual use in a post-harness assembly area, for example, to further trim and group the wiring harnesses within the breakouts. The wire harness assembly system 100 may route wire harnesses on top of these wire harness routing supports 514 .

[0058] In one example, the harness assembly system 100 includes a pipe conveyor station, a harness assisted operation station, a shuttle system, a selectively compliant articulated robotic arm, a 7-axis robot, a control station, a safety unit enclosure, a LIDAR ankle detector, a light fence, and a maintenance unit. The pipe assembly jig 202 is received from the pipe preparation area and can be manually loaded onto one end of the pipe conveyor, which supports the full length of the pipe assembly jig 202. The pipe conveyor ingests the pipe assembly jig 202 and positions it within the harness assembly system 100. The harness assisted operation station, the shuttle system, the selectively compliant articulated robotic arm, and the 7-axis robot are positioned adjacent to the pipe assembly jig 202 to remove individual wire harnesses 300 from carriers on the harness delivery system 104 and supply them to the shuttle system. Empty carriers continue through the harness delivery system 104 to be refilled at the harness preparation system 102. The shuttle system is an automated system positioned adjacent to the pipe assembly jig 202. The shuttle system includes two shuttles, each of which holds one end of the wire harness 300 and is movable along the guide rails to draw out the wire harness and position the wire harness next to the pipe assembly fixture 202 .

[0059] Selective compliant articulated robotic arms are positioned, for example, every 24 inches beside the pipe assembly fixture 202. These robotic arms include end effectors that can pick up the wire harnesses 300 from the guide rails of the shuttle system and place the wire harnesses 300 into the longitudinal and branch wire harness routing supports 514 in the pipe assembly fixture 202.

[0060] The 7-axis robot includes two 6-axis robots, each of which is mounted on a guide rail (i.e., the seventh axis) next to the pipe assembly fixture 202, between the shuttle system and the selectively compliant articulated robotic arm. The 7-axis robot includes an end effector that can pick up a wire harness from the shuttle of the shuttle system and insert the end of the wire harness 300 into the connectors 512, 518 installed in the pipe assembly fixture 202. For example, the electrical contacts of a single-conductor unshielded wire harness are robotically inserted into the cavities of the connectors 512, 518. The process uses a vision system and force / torque feedback technology to complete the insertion. Similarly, the modular connector insert of the cable is robotically inserted into the opening of the modular connector socket installed in the pipe assembly fixture 202. The process also uses a vision system and force / torque feedback technology to complete the insertion.

[0061] The control station provides a human-machine interface for the operator. The human-machine interface is located at both ends of the pipe assembly fixture 202. The safety unit enclosure surrounds the pipe transfer station, auxiliary operation station, shuttle system, selective compliance articulated robotic arm and most of the 7-axis robot (including their guide rails). The safety unit can span several adjacent wire harness assembly systems 100. A portion (or some portions) of the pipe transfer station can be outside the safety unit wall to facilitate loading and unloading of the pipe assembly fixture 202 from the pipe preparation area. Even when adjacent wire harness assembly systems 100 are operating within the safety enclosure, tunnels and light gates can be used to separate the operator from the activities within the safety enclosure while providing a means for loading and unloading the pipe assembly fixture 202. The wire harness conveying system 104 brings the wire harness 300 to the auxiliary operation station located within the safety enclosure and transports the empty conveying carrier outside the safety enclosure.

[0062] LIDAR ankle detectors monitor the area just above the floor within the safety enclosure to detect operator entry. These detectors detect an operator in the harness assembly system 100 and ensure that the harness assembly system 100 and adjacent harness assembly systems 100 operate in slow mode when the operator holds the control pendant safety button in a neutral position (i.e., not fully pressed and not fully released). The light fence will separate the individual harness assembly systems 100 from each other. If the light fence is triggered, two adjacent harness assembly systems 100 operate in slow mode when the operator holds the control pendant safety button in a neutral position (i.e., not fully pressed and not fully released). This mode should be maintained until the LIDAR ankle detectors do not detect an operator and the operator resumes operation at the control station for each production line. The maintenance unit is an area used for equipment repair, maintenance and spare parts storage.

[0063] Figures 13 to 36 Various examples of methods 1400, 1500, and 3000 for assembling electrical conduit modules are shown in FIG. Methods 1400, 1500, and 3000 for assembling electrical conduit modules include receiving a wire harness 300 and routing the wire harness 300 in a conduit assembly jig 202. An operator at the input of the harness assembly system 100 can load the conduit assembly jig 202 from outside the safety enclosure onto a transfer table. The harness assembly system 100 ingests the conduit through the safety enclosure via a tunnel that also has a light barrier to prevent the operator or their limbs from entering. Once the entire conduit assembly jig 202 has been fed onto the transfer table, it positions and locks it in place. The operator initiates production via a human-machine interface. Individual wire harnesses 300 arrive on a carrier from the harness delivery system 104. An auxiliary handling robot removes the coiled wire harness 300 from the carrier and places it on an unwinder, simultaneously placing each end of the wire harness 300 into a first end holder and a second end holder. These end retainers hold the electrical contacts or modular connector inserts on each end of the harness in a repeatable, controllable position and orientation. A second end retainer is located on the rotating portion of the unwinder reel. Note that the harness delivery system 104 can then move out of the empty carrier and bring in the next harness 300 in the next carrier.

[0064] The first end of the wire harness 300 is then transferred by the auxiliary handling robot to the first shuttle of the wire harness shuttle system. As the first shuttle pulls the wire harness outward along the shuttle guide at a speed of, for example, approximately 6 feet per second, the wire harness 300 rotates in the uncoiler to feed the wire harness 300. Note that the second end of the wire harness 300 will rotate with the uncoiler disk. For example, for the last foot of wire harness extending from the uncoiler, the first shuttle slows to approximately one foot per second. As the wire harness 300 is unwound, as detected by the camera, the auxiliary handling robot transfers the second end from the uncoiler to the second shuttle. Note that the auxiliary handling robot can then begin picking up the next wire harness 300 from the wire harness delivery system 104 and placing the wire harness 300 on the uncoiler.

[0065] The shuttle system positions the harness at a target center point next to the pipe assembly fixture 202, moving at, for example, approximately 6 feet per second. The first shuttle can position the first end of the harness 300 to approximately 99% of the distance beyond half of the target center point of the harness 300. The second shuttle can position the second end of the harness 300 to approximately 99% of the distance from half of the target center point of the harness 300. The shuttles slowly move away from each other until, for example, at least one of the first and second shuttles detects approximately three pounds of tension. Both shuttles then stop and retract, for example, approximately 0.4% of the length of the harness 300. The harness 300 is now relatively centered about the target position, stretched out, and no longer under tension, with any length tolerance evenly distributed between the first and second ends of the harness. Note that both shuttles include force sensors, but both shuttles stop after either force sensor detects a predetermined force threshold (e.g., three pounds of tension).

[0066] The two 7-axis robots and the selective compliant articulated manipulator between the two 7-axis robots move to pick up the wire harness from the shuttle system. The two 7-axis robots grab the contacts / inserts at the first and second ends of the wire harness 300. After picking up the wire harness 300 from the shuttle system, the shuttle retracts to its home position to receive the next wire harness 300. The two 7-axis robots and the active selective compliant articulated manipulator move the wire harness 300 to the pipe assembly fixture 202, just above the longitudinal wire harness routing support 514. The selective compliant articulated manipulator places the wire harness in the longitudinal wire harness routing support 514 and, for wire harnesses 300 branching from the longitudinal routing channel 516, places the wire harness in any applicable wire harness routing support 522 while the two 7-axis robots continue to hold the wire harness ends. The selective compliant articulated manipulator then begins to retract to its home position.

[0067] Two 7-axis robots move the wire harness ends to a point just above the corresponding target electrical connectors 512, following a high path on a spherical surface centered on the last longitudinal wire harness routing support 514 or branch support 522. This high spherical path prevents slack in the wire harness 300 from becoming tangled on any formboard features. The two 7-axis robots move to the reference points of the target electrical connectors 512, 518. Using the insertion subroutine, the two 7-axis robots insert the terminated ends of the wire harness 300 into the connectors 512, 518 and perform a retention test. The two 7-axis robots retract and, if necessary, reposition for the next wire harness 300. The above process repeats until the remaining wire harnesses 300 to be placed in the conduit assembly fixture 202 have been placed. An operator at the output of the harness assembly system 100 unloads the conduit for transfer to the rear harness assembly area 108. This is accomplished by, for example, pressing and holding an unload button on the human-machine interface, causing the transfer table to transport the conduit assembly fixture out of the harness assembly system and into the rear harness assembly area 108.

[0068] Overall reference Figures 1 to 7 By way of example, the present disclosure relates to a wire harness assembly system 100 for assembling an electrical conduit module. Figure 1 An example of a manufacturing system for assembling a wire harness 300 , a conduit assembly fixture 202 , and an electrical conduit module is shown. Figure 2 An example of a wire harness assembly system 100 for assembling an electrical conduit module is shown. Figure 3 An example of a wire harness 300 is shown. Figure 4 Shown for transport Figure 3 1 and 2. An example of a wire harness carrier 400 of the wire harness 300 is shown. Figure 5 Shown Figure 2 1. An example of a conduit assembly fixture 202 of the wire harness assembly system 100. Figure 6 Another example of a wire harness assembly system 100 for assembling an electrical conduit module is shown. Figure 7 Shown Figure 6 An example of a harness shuttle subsystem 208 of the harness assembly system 100 is shown.

[0069] Reference again Figures 1 to 7In one or more examples, the harness assembly system 100 for assembling electrical conduit modules includes a conduit assembly fixture 202, a harness shuttle subsystem 208, at least one robotic manipulator 218, and a system controller 220. The conduit assembly fixture 202 is disposed on a top surface 204 of a workpiece support structure 206. The harness shuttle subsystem 208 includes a first shuttle 210 disposed on an upper surface 212 of a tool support structure 214 and a second shuttle 216 disposed on the upper surface 212. The at least one robotic manipulator 218 is disposed on the upper surface 212 of the tool support structure 214. The system controller 220 is in operative communication with the harness shuttle subsystem 208 and the at least one robotic manipulator 218 to control placement of a harness 300 from the first shuttle 210 and the second shuttle 216 to the conduit assembly fixture 202.

[0070] In another example of the wire harness assembly system 100, the electrical conduit module is configured to be installed in the end product as a modular component of an electrical conduit architecture for the end product. In another example, the end product includes an aircraft, a rotorcraft, a bus, a passenger transport vehicle, a military transport vehicle, a combat military vehicle, a power plant, an unmanned aerial vehicle, a ship, a ferry, a cruise ship, a naval vessel, a commercial building, and a residential building, or any other suitable end product in any other suitable combination. In yet another example of the wire harness assembly system 100, the electrical conduit module is about 4 inches wide to about 36 inches wide, about 8 inches wide to about 24 inches wide, about 14 inches wide to about 18 inches wide, or any other suitable width size. In yet another example of the wire harness assembly system 100, the electrical conduit module is about two feet long to about 100 feet long, about ten feet long to about 80 feet long, about 20 feet long to about 60 feet long, about 30 feet long to about 50 feet long, about 40 feet long, or any other suitable length size.

[0071] In yet another example of the wire harness assembly system 100, the workpiece support structure 206 comprises a transport table. In another example, the transport table comprises a mobile cart, a work table with rollers on its top side, a support structure with a conveyor belt, or any other suitable transport table in any suitable combination. In another example of the wire harness assembly system 100, the at least one robotic manipulator 218 comprises at least one robotic arm, at least one 4-axis robotic arm, at least one 6-axis robotic arm, at least one 7-axis robotic arm, at least one selectively compliant articulated robotic arm, at least one collaborative robot, at least one electromechanical manipulator, at least one automatic mechanical manipulator, at least one semi-automatic mechanical manipulator, at least one fixed actuator assisted operation robot, at least one semi-manually operated robot, or any other type of robotic manipulator in any suitable combination.

[0072] In yet another example of the wire harness assembly system 100, the wire harness assembly system 100 is configured to receive the wire harness 300 on a wire harness carrier 400 from the wire harness preparation system 102 via the wire harness delivery system 104. In another example, the wire harness carrier 400 includes at least one coil holder 402, a first end clamp 404, a second end clamp 406, and a wire harness carrier identification element 408. In a further example, the wire harness carrier identification element 408 includes a serial number, a bar code, a machine-readable code, a quick response code, a glyph code, a radio frequency identification tag, a radio frequency identification label, or any other suitable identification element in any suitable combination. In another example, upon receipt, the wire harness 300 includes a coil 302 having a disconnect point 304 at which a first termination end 306 of the wire harness 300 and a second termination end 308 of the wire harness 300 are separated from the coil 302. The wiring harness 300 also includes a first harness marker 310 proximate the first termination end 306 and a second harness marker 312 proximate the second termination end 308. In yet another example, the wiring harness 300 includes single conductors, twisted-pair conductors, multi-conductor cables, shielded cables, unjacketed cables, coaxial cables, impedance-matched cables, fiber optic cables, or any other suitable type of wiring harness or cables in any suitable combination.

[0073] In another example of the wire harness assembly system 100, the duct assembly fixture 202 includes a duct frame 502, an electrical connector 512, and a wire harness routing support 514. The duct frame 502 includes longitudinal side panels 504, transverse end panels 506, longitudinal support members 508 between the transverse end panels 506, and transverse support members 510 between the longitudinal side panels 504. The electrical connector 512 is positioned adjacent to the transverse end panels 506. The wire harness routing support 514 is mounted on the transverse support members 510 to define a longitudinal routing channel 516. In another example, the electrical connector 512 includes a modular connector, a standard connector, or any other suitable type of connector in any suitable combination. In another example, the duct assembly fixture 202 also includes at least one additional electrical connector 518, at least one printed circuit board 520, and a branch wiring support 522. The at least one additional electrical connector 518 is positioned adjacent to at least one of the longitudinal side panels 504. At least one printed wiring board 520 is mounted on one or more of the longitudinal side panels 504, one or more of the transverse end panels 506, one or more of the longitudinal support members 508, one or more of the transverse support members 510, or any other suitable mounting surface in any suitable combination. Branch wiring supports 522 are mounted on the transverse support members 510 to define transverse routing channels 524 branching from one or more of the longitudinal routing channels 516.

[0074] In yet another example of the wire harness assembly system 100, the first shuttle 210 is configured to receive and temporarily hold a first termination end 306 of a wire harness 300, and the second shuttle 216 is configured to receive and temporarily hold a second termination end 308 of the wire harness 300. The system controller 220 and the harness shuttle subsystem 208 are configured to position the first shuttle 210 and the second shuttle 216 to longitudinally extend the wire harness 300 on the upper surface 212 of the tool support structure 214. In another example, the system controller 220, the harness shuttle subsystem 208, and the at least one robotic manipulator 218 are configured to place the wire harness 300 having the first termination end 306 and the second termination end 308 at a predetermined position in the pipe assembly fixture 202.

[0075] In another further example, the at least one robotic manipulator 218 includes at least one transfer robotic manipulator 602 mounted on the upper surface 212 of the tool support structure 214. The at least one transfer robotic manipulator 602 is configured to pick up the wiring harness 300 from between the first shuttle 210 and the second shuttle 216 and place the wiring harness 300 in one or more wiring harness routing supports 514 at predetermined locations in the tube assembly fixture 202. In yet another further example, the at least one transfer robotic manipulator 602 includes at least one robotic arm, at least one selectively compliant articulated robotic arm, at least one collaborative robot, or any other suitable robotic manipulator in any suitable combination. In yet another further example, the at least one transfer robotic manipulator 602 includes a plurality of transfer robotic manipulators 602 spaced longitudinally along the upper surface 212 of the tool support structure 214. In yet another further example, the plurality of transfer robotic manipulators 602 are spaced at least one of about one foot to about two feet, about two feet to about three feet, about three feet to about four feet, or any other suitable spacing in any suitable combination.

[0076] In yet another example, the at least one robotic manipulator 218 includes at least one insertion robotic manipulator 604 disposed on the upper surface 212 of the tool support structure 214, the at least one insertion robotic manipulator 604 being configured to pick up the first termination end 306 of the wire harness 300 from the first shuttle 210 and insert the first termination end 306 into a predetermined starting electrical connector 512, 518 at a first predetermined location in the pipe assembly fixture 202. In yet another example, the at least one insertion robotic manipulator 604 includes at least one robotic arm, at least one 6-axis robotic arm, at least one 7-axis robotic arm, at least one collaborative robot, or any other suitable robotic manipulator in any suitable combination. In yet another example, the at least one insertion robotic manipulator 604 is configured to pick up the second termination end 308 of the wire harness 300 from the second shuttle 216 and insert the second termination end 308 into a predetermined target electrical connector 512, 518 at a second predetermined location in the pipe assembly fixture 202.

[0077] In yet another example, the at least one robotic manipulator 218 includes a first insertion robotic manipulator 606 and a second insertion robotic manipulator 610. The first insertion robotic manipulator 606 is mounted on a first robotic transfer unit 608, which is disposed on the upper surface 212 of the tool support structure 214 and is configured to translate the first insertion robotic manipulator 606 along the length of the pipe assembly fixture 202. The first insertion robotic manipulator 606 is configured to cooperate with the first robotic transfer unit 608 to pick up the first termination end 306 of the wire harness 300 from the first shuttle 210 and insert the first termination end 306 into a predetermined starting electrical connector 512, 518 at a first predetermined position in the pipe assembly fixture 202. The second insertion robotic manipulator 610 is mounted on a second robotic transfer unit 612, which is disposed on the upper surface 212 adjacent to the first robotic transfer unit 608 and is configured to translate the second insertion robotic manipulator 610 along the length of the pipe assembly fixture 202. The second insertion robotic manipulator 610 is configured to cooperate with the second robotic transfer unit 612 to pick up the second termination end 308 of the wire harness 300 from the second shuttle 216 and insert the second termination end 308 into the predetermined target electrical connector 512 , 518 at a second predetermined position in the pipe assembly fixture 202 .

[0078] In yet another example of the harness assembly system 100, the harness shuttle subsystem 208 further includes a longitudinal groove 702, a first conveyor assembly 704, a second conveyor assembly 708, an unwinder assembly 712, an image sensor 714, a harness carrier identification detector 715, and a control assembly 716. The longitudinal groove 702 is disposed on the upper surface 212 of the tool support structure 214 and extends alongside / along the conduit assembly fixture 202. The first conveyor assembly 704 is mechanically coupled to the first shuttle 210 to position the first shuttle 210 along the first longitudinal track 706 of the longitudinal groove 702. The second conveyor assembly 708 is mechanically coupled to the second shuttle 216 to position the second shuttle 216 along the second longitudinal track 710 of the longitudinal groove 702. The uncoiler assembly 712 is disposed on the upper surface 212 of the tool support structure 214 and is configured to hold the coil 302 of the wire harness 300, the first termination end 306 of the wire harness 300, and the second termination end 308 of the wire harness 300. An image sensor 714 is located proximate to the uncoiler assembly 712 and is configured to selectively capture images of the first termination end 306 and the second termination end 308, as well as an image showing the state of the coil 302 on the uncoiler assembly 712. A wire carrier identification detector 715 is located proximate to the wire carrier 400 on the wire harness delivery system 104. The wire carrier 400 is configured to deliver the wire harness 300 from the wire harness preparation system 102 to the wire harness assembly system 100. The wire carrier identification detector 715 is configured to selectively capture an identification number from the wire carrier identification element 408 on the wire carrier 400. The control assembly 716 operatively communicates with the first conveyor assembly 704, the second conveyor assembly 708, the uncoiler assembly 712, the image sensor 714, the harness carrier identification detector 715, and the system controller 220 to control the transfer of the first termination end 306 from the uncoiler assembly 712 to the first shuttle 210, the movement of the first shuttle 210 along the first longitudinal track 706, the unwinding of the coil 302 from the uncoiler assembly 712, the placement of the second termination end 308 from the uncoiler assembly 712 to the second shuttle 216, and the movement of the second shuttle 216 along the second longitudinal track 710.

[0079] In another example, the first conveying assembly 704 includes a stepper motor, a DC motor, an encoder device, a position sensor, a belt drive assembly, a screw drive assembly, a chain drive assembly, or any other suitable drive element in any suitable combination. In another further example, the second conveying assembly 708 includes a stepper motor, a DC motor, an encoder device, a position sensor, a belt drive assembly, a screw drive assembly, a chain drive assembly, or any other suitable drive element in any suitable combination. In another example, the image sensor 714 includes a digital camera, a charge coupled device, an active pixel device, an optical scanner, a laser scanner, or any other suitable image sensor in any suitable combination. In another example, the harness carrier identification detector 715 includes a digital camera, a charge coupled device, an active pixel device, an optical scanner, a laser scanner, a radio frequency identification reader, a radio frequency identification transponder, or any other suitable detector in any other suitable combination.

[0080] In a further example, the unwinder assembly 712 includes a rotatable plate 718, a first end retainer 720, and a second end retainer 722. The rotatable plate 718 is configured to temporarily retain the coil 302 of the wire harness 300 and unwind the wire harness 300 in response to tension on the first termination end 306 in conjunction with movement of the first shuttle 210 along the first longitudinal track 706 of the harness shuttle subsystem 208. The first end retainer 720 is disposed proximate to the rotatable plate 718 and is configured to temporarily retain the first termination end 306 of the wire harness 300. The second end retainer 722 is mounted on the rotatable plate 718 and is configured to retain the second termination end 308 of the wire harness 300. In a further example, the first end retainer 720 includes the first shuttle 210 proximate to the rotatable plate 718 when positioned on the first longitudinal track 706 of the longitudinal groove 702. In another further example, the wire harness assembly system 100 further includes an auxiliary operation robotic manipulator 614 mounted on a support platform 616 adjacent to a proximal region 618 of the tool support structure 214. The auxiliary operation robotic manipulator 614 is configured to pick up the coil 302, the first termination end 306, and the second termination end 308 of the wire harness 300 from the wire harness carrier 400 on the wire harness delivery system 104. The auxiliary operation robotic manipulator is further configured to place the coil 302 on the rotatable plate 718 of the uncoiler assembly 712, place the first termination end 306 on the first end holder 720, and place the second termination end 308 on the second end holder 722.

[0081] In a further example, the assistive robotic manipulator 614 includes a robotic arm, a 6-axis robotic arm, a collaborative robot, an electromechanical manipulator, an automatic mechanical manipulator, a semi-automatic mechanical manipulator, a fixed actuator assistive robot, a semi-manual robot, or any other suitable type of robotic manipulator in any suitable combination. In another further example, the system controller 220 and the assistive robotic manipulator 614 are configured to pick up the first termination end 306 of the wire harness 300 from the first end holder 720 and place the first termination end 306 on the first shuttle 210. The system controller 220 and the assistive robotic manipulator 614 are further configured to pick up the second termination end 308 of the wire harness 300 from the second end holder 722 and place the second termination end 308 on the second shuttle 216 after the system controller 220 detects that the wire harness 300 is unwound from the rotatable plate 718.

[0082] In an alternative example, a second assistive robotic manipulator, or any other robotic manipulator, may be used to pick up the first terminated end 306 of the wire harness 300 from the first end holder 720 and place the first terminated end 306 on the first shuttle 210. In a similar alternative example, after the system controller 220 detects that the wire harness 300 is unwound from the rotatable plate 718, a second assistive robotic manipulator, or any other robotic manipulator, may be used to pick up the second terminated end 308 of the wire harness 300 from the second end holder 722 and place the second terminated end 308 on the second shuttle 216. These alternative examples allow the assistive robotic manipulator 614 to prepare to transfer the next wire harness 300 from the wire carrier 400 to the uncoiler assembly 712 while the current wire harness 300 is unwound from the rotatable plate 718.

[0083] Overall reference Figures 1 to 7 、 Figure 12 and Figures 14 to 29 By way of example, the present disclosure relates to a method 1400 , 1500 for assembling an electrical conduit module. Figure 1 An example of a manufacturing system for assembling a wire harness 300 , a conduit assembly fixture 202 , and an electrical conduit module is shown. Figure 2 An example of a wire harness assembly system 100 for assembling an electrical conduit module is shown. Figure 3 An example of a wire harness 300 is shown. Figure 4 Shown for transport Figure 3 1 and 2. An example of a wire harness carrier 400 of the wire harness 300 is shown. Figure 5 Shown Figure 2 1. An example of a conduit assembly fixture 202 of the wire harness assembly system 100. Figure 6 Another example of a wire harness assembly system 100 for assembling an electrical conduit module is shown. Figure 7 Shown Figure 6 An example of a harness shuttle subsystem 208 of the harness assembly system 100 is shown. Figure 12 Shown Figure 6 An example of an assistive operation robotic manipulator 614 in the wire harness assembly system 100 .

[0084] Figure 14 An example of a method 1400 for assembling an electrical conduit module is provided. Figure 15 and Figure 14 In combination, an example of a method 1500 for assembling an electrical conduit module is provided. Figure 16 Provided in Figure 14 An example of receiving 1402 a pipe assembly fixture in method 1400 is shown. Figure 17 Provided in Figure 14 Another example of receiving 1402 a pipe assembly fixture in method 1400 is provided. Figure 18 Provided in Figure 14 An example of receiving 1404 of the harness 300 in the method 1400 is shown. Figure 19 Provided Figure 18 An example of picking up 1802 of the coil 302 of the harness 300 . Figure 20 Provided Figure 18 An example of placement 1804 of the coil 302 , the first terminating end 306 , and the second terminating end 308 ; Figure 21 Shown Figure 12 An example of an end effector 2100 that assists in manipulating the robotic manipulator 614 . Figure 22 is Figure 14 A flow chart of an example of a method 1400 for harness positioning. Figure 23 Shown Figure 22 22. An example of movement 2210 of first shuttle 210 is shown. Figure 24 Shown Figure 22 22. An example of movement 2212 of second shuttle 216 is shown. Figure 25 Shown in Figure 14 An example of picking 1408 of the wire harness 300 in the method 1400 . Figure 26 Shown in Figure 14 An example of placement 1410 of the harness 300 in the method 1400 is shown. Figure 27 Shown in Figure 14 Another example of picking 1408 and placing 1410 of the wire harness 300 in the method 1400 is shown. Figure 28 and Figure 27 The combination shows Figure 14 1400 . FIG. 1404 is another example of picking 1408 and placing 1409 of the wire harness 300 in the method 1400 . Figure 29 and Figure 27and Figure 28 The combination shows Figure 14 1400 . FIG. 1404 is another example of picking 1408 and placing 1410 of the wire harness 300 in the method 1400 .

[0085] Reference again Figures 1 to 7 、 Figure 12 and Figures 14 to 29 In one or more examples, a method 1400 for assembling an electrical conduit module (see Figure 14 ) includes receiving 1402 the conduit assembly fixture 202 from the conduit preparation area 106 on a workpiece support structure 206. The workpiece support structure 206 is adjacent to the tool support structure 214. At 1404, a wire harness 300 is received from the harness preparation system 102 for placement in the conduit assembly fixture 202. The wire harness 300 includes a first termination end 306 and a second termination end 308. At 1406, the wire harness 300 is positioned on the upper surface 212 of the tool support structure 214 between a first shuttle 210 holding the first termination end 306 and a second shuttle 216 holding the second termination end 308. At 1408, the wire harness 300 having the first termination end 306 and the second termination end 308 is picked up from the upper surface 212 of the tool support structure 214, the first shuttle 210, and the second shuttle 216. At 1410 , the wire harness 300 is placed at a predetermined location in the conduit assembly fixture 202 .

[0086] In another example of method 1400, the electrical conduit module is configured to be installed in an end product as a modular component of an electrical conduit architecture for the end product. In another example, the end product includes an aircraft, a rotorcraft, an unmanned aerial vehicle, a bus, a passenger transport vehicle, a military transport vehicle, a combat military vehicle, a passenger ship, a cargo ship, a naval vessel, a commercial building, a residential building, or any other suitable end product in any other suitable combination. In yet another example of method 1400, the electrical conduit module is approximately 4 inches wide to approximately 36 inches wide, approximately 8 inches wide to approximately 24 inches wide, approximately 14 inches wide to approximately 18 inches wide, or any other suitable width dimension. In yet another example of method 1400, the electrical conduit module is approximately two feet long to approximately 100 feet long, approximately ten feet long to approximately 80 feet long, approximately 20 feet long to approximately 60 feet long, approximately 30 feet long to approximately 50 feet long, approximately 40 feet long, or any other suitable length dimension.

[0087] In yet another example of method 1400, the workpiece support structure 206 includes a transfer table. In another example, the transfer table includes a mobile cart, a work table with rollers on a top side, a support structure with a conveyor belt, or any other suitable transfer table in any suitable combination. In another example, method 1400 is implemented in a wire harness assembly system 100, which is configured to receive the wire harness 300 on the wire harness carrier 400 from the wire harness preparation system 102 via the wire harness delivery system 104. In another example, when received, the wire harness 300 includes a coil 302 having a disconnection point 304 at which a first termination end 306 of the wire harness 300 and a second termination end 308 of the wire harness 300 are separated from the coil 302. The wire harness 300 also includes a first harness marker 310 proximate the first termination end 306 and a second harness marker 312 proximate the second termination end 308. In another example, the wiring harness 300 includes single conductors, twisted pair conductors, multi-conductor cables, shielded cables, unjacketed cables, coaxial cables, impedance matched cables, fiber optic cables, or any other suitable type of wiring harness or cable in any suitable combination.

[0088] Reference again Figures 1 to 3 、 Figure 14 and Figure 15 In one or more examples, a method 1500 for assembling an electrical conduit module (see Figure 15 )include Figure 14 The method 1400 is repeated from 1410 to 1502, where the receiving 1402, 1404, positioning 1406, picking 1408, and placing 1410 of the harness 300 are repeated for the next harness 300 until all harnesses designated for autonomous placement in the conduit assembly fixture 202 are placed. In another example, the method 1500 also includes transferring 1504 the conduit assembly fixture 202 to a post-harness assembly area 108 for a manual assembly process on the conduit assembly fixture 202 to prepare the electrical conduit module for installation in the final product.

[0089] Reference again Figures 1 to 7 、 Figure 12 and Figures 14 to 29 In another example of the method 1400, receiving 1402 the pipe assembly fixture 202 includes receiving 1602 the pipe assembly fixture 202 from the pipe preparation area 106 via the pipe delivery system (see Figure 16) the pipe assembly fixture 202. At 1604, the pipe assembly fixture 202 is transferred from the pipe transport system to the top surface 204 of the workpiece support structure 206. At 1606, the workpiece support structure 206 with the pipe assembly fixture 202 is moved 1606 alongside the tool support structure 214. At 1608, the workpiece support structure 206 is locked in place. In yet another example of the method 1400, receiving 1402 the pipe assembly fixture 202 includes transporting 1702 (see FIG. 1 ) from the pipe preparation area 106 on the workpiece support structure 206. Figure 17 ) The pipe assembly fixture 202. At 1704, the workpiece support structure 206 with the pipe assembly fixture 202 is moved alongside the tool support structure 214. At 1706, the workpiece support structure 206 is locked in place.

[0090] In yet another example of the method 1400, receiving 1404 the wire harness 300 includes picking 1802 from the wire harness carrier 400 on the wire harness delivery system 104 using the auxiliary handling robotic manipulator 614 mounted on the support platform 616 adjacent to the proximal region 618 of the tool support structure 214 (see Figure 18 ) a coil 302 of the wiring harness 300 having a first termination end 306 and a second termination end 308. At 1804, the coil 302, the first termination end 306, and the second termination end 308 are placed on the uncoiler assembly 712 disposed on the upper surface 212 at the proximal region 618 of the tool support structure 214 using the auxiliary operation robotic manipulator 614. In another example, the picking up 1802 of the coil 302 includes picking up 1902 the coil 302 of the wiring harness 300 from at least one coil holder 402 of the wiring harness carrier 400 using at least one first holding device 2102 of the end effector 2100 attached to the auxiliary operation robotic manipulator 614. At 1904, the first termination end 306 of the wiring harness 300 is picked up from the first end gripper 404 of the wiring harness carrier 400 using the second holding device 2104 of the end effector 2100. At 1906 , the second terminating end 308 of the wire harness 300 is picked up from the second end gripper 406 of the wire carrier 400 using the third holding device 2106 of the end effector 2100 .

[0091] In another further example, the placing 1804 of the coil 302 includes placing 2002 the coil 302 of the harness 300 from at least one first holding device 2102 attached to the end effector 2100 of the auxiliary operation robotic manipulator 614 (see Figure 20) on the rotatable plate 718 of the uncoiler assembly 712. At 2004, the first terminated end 306 of the wire harness 300 is placed from the second retaining device 2104 of the end effector 2100 onto the first end retainer 720 of the uncoiler assembly 712. At 2006, the second terminated end 308 of the wire harness 300 is placed from the third retaining device 2106 of the end effector 2100 onto the second end retainer 722 of the uncoiler assembly 712. In a further example, the first end retainer 720 includes the first shuttle 210 when positioned proximate to the rotatable plate 718.

[0092] In yet another example of the method 1400, the coil 302 of the wire harness 300 having the first termination end 306 and the second termination end 308 is positioned at the uncoiler assembly 712 located on the upper surface 212 at the proximal region 618 of the tool support structure 214. In this example, positioning 1406 the wire harness 300 includes capturing 2202 from the wire carrier identification element 408 on the wire carrier 400 of the wire transport system 104 (see Figure 22 ) identification number. The identification number uniquely identifies the wire harness carrier 400 relative to other wire harness carriers on the wire harness delivery system 104. The identification number is correlated to a unique harness number associated with the wire harness 300 and the other wire harnesses of the electrical conduit module. At 2204, a location in the conduit assembly fixture 202 for placement of the wire harness 300, the first termination end 306 of the wire harness 300, and the second termination end 308 of the wire harness 300 is determined based at least in part on the identification number. At 2206, the first shuttle 210 is moved along the first longitudinal track 706 to a first pick position proximate to the uncoiler assembly 712. At 2208, the first termination end 306 of the wire harness 300 is placed in the first shuttle 210 using an auxiliary operation robotic manipulator 614 mounted on a support platform 616 adjacent to the proximal region 618 of the tool support structure 214. At 2210, the first shuttle 210 with the first termination end 306 is moved away from the uncoiler assembly 712 and the rotatable plate 718 of the uncoiler assembly 712 is rotated until the coil 302 of the wire harness 300 is completely unwound. At 2212, the second shuttle 216 is moved along the second longitudinal track 710 to a second pick-up position adjacent to the uncoiler assembly 712. At 2214, the second termination end 308 of the wire harness 300 is placed from the second end holder 722 on the uncoiler assembly 712 into the second shuttle 216 using the auxiliary operation robotic manipulator 614. At 2216, the first shuttle 210 with the first termination end 306 and the second shuttle 216 with the second termination end 308 are moved away from the uncoiler assembly 712 until the wire harness 300 is positioned adjacent to the target location for the wire harness 300 in the conduit assembly fixture 202.

[0093] In another example, the movement 2210 of the first shuttle 210 and the rotation of the rotatable plate 718 include capturing 2302 when the coil 302 of the harness 300 is unwound (see FIG. Figure 23 ) a series of visual images of the rotatable plate 718. At 2304, it is determined that the coil 302 of the harness 300 is unwound from the rotatable plate 718 based at least in part on the series of visual images. At 2306, once the coil 302 is unwound, the movement 2210 of the first shuttle 210 and the rotation of the rotatable plate 718 are stopped.

[0094] In another further example, the first shuttle 210 includes a first force sensor 724 and the second shuttle 216 includes a second force sensor 726. The movement 2216 of the first shuttle 210 and the movement of the second shuttle 216 include stopping 2402 after the harness 300 is positioned next to the target location of the harness 300 (see Figure 24 ) Movement 2216 of the first shuttle 210 and movement of the second shuttle 216. At 2404, the first shuttle 210 is slowly moved away from the target location of the wiring harness 300. At 2406, the second shuttle 216 is slowly moved away from the target location of the wiring harness 300. At 2408, after at least one of the first force sensor 724 and the second force sensor 726 detects that the tension on the wiring harness 300 exceeds a predetermined tension threshold, the opposing movements of the first shuttle 210 and the second shuttle 216 are stopped. At 2410, the first shuttle 210 and the second shuttle 216 are retracted a predetermined amount to remove the tension and relatively center the first termination end 306 of the wiring harness 300 and the second termination end 308 of the wiring harness 300 relative to the target location of the wiring harness 300.

[0095] In a further example, the predetermined tension threshold comprises about one pound of tension to about five pounds of tension, about two pounds of tension to about four pounds of tension, about three pounds of tension, or any other suitable amount of tension. In another further example, the predetermined retraction amount toward the target position of the harness 300 comprises about 0.1% to about 0.7% of the length of the harness 300, about 0.2% to about 0.6% of the length of the harness 300, about 0.3% to about 0.5% of the length of the harness 300, about 0.4% of the length of the harness 300, or any other suitable retraction distance.

[0096] In another example of the method 1400, picking up 1408 the harness 300 includes moving 2502 toward the first shuttle 210 (see Figure 25) A first insertion robotic manipulator 606 on a first robotic transfer unit 608 is moved. The first insertion robotic manipulator 606 is mounted on the first robotic transfer unit 608. The first robotic transfer unit 608 is disposed on the upper surface 212 of the tool support structure 214. At 2504, the first termination end 306 of the wire harness 300 is picked up from the first shuttle 210 using the first insertion robotic manipulator 606. At 2506, a second insertion robotic manipulator 610 on a second robotic transfer unit 612 is moved toward the second shuttle 216. The second insertion robotic manipulator 610 is mounted on the second robotic transfer unit 612. The second robotic transfer unit 612 is disposed adjacent to the first robotic transfer unit 608 on the upper surface 212 of the tool support structure 214. At 2508, the second termination end 308 of the wire harness 300 is picked up from the second shuttle 216 using the second insertion robotic manipulator 610. At 2510, the wire harness 300 between the first termination end 306 and the second termination end 308 is picked up using at least one transfer robotic manipulator 602 mounted on the upper surface 212 of the tool support structure 214 adjacent to the first robotic transfer unit 608 or the second robotic transfer unit 612. In another example, the plurality of transfer robotic manipulators 602 between the first termination end 306 of the wire harness 300 and the second termination end 308 of the wire harness 300 are spaced a predetermined distance along the upper surface 212 of the tool support structure 214. In yet further examples, the predetermined distance includes about one foot to about three feet, about 1.5 feet to about 2.5 feet, about two feet, or any other suitable distance.

[0097] In yet another example of the method 1400, placing 1410 the wire harness 300 includes placing 2602 the wire harness 300 between the first termination end 306 and the second termination end 308 using at least one transfer robotic manipulator 602 mounted adjacent to the upper surface 212 of the tool support structure 214 with either a first robotic transfer unit 608 associated with the first insertion robotic manipulator 606 or a second robotic transfer unit 612 associated with the second insertion robotic manipulator 610 (see FIG. 1 ). Figure 26) in the wire harness routing support 514 of the predetermined longitudinal routing channel 516 in the pipe assembly fixture 202. The first insertion robotic manipulator 606 is mounted on the first robotic transfer unit 608. The first robotic transfer unit 608 is disposed on the upper surface 212 of the tool support structure 214. The second insertion robotic manipulator 610 is mounted on the second robotic transfer unit 612. The second robotic transfer unit 612 is disposed on the upper surface 212 of the tool support structure 214. At 2604, the first termination end 306 of the wire harness 300 is positioned in the predetermined starting electrical connector 512, 518 in the pipe assembly fixture 202 using the first insertion robotic manipulator 606. At 2606, the second termination end 308 of the wire harness 300 is placed in the predetermined target electrical connector 512, 518 in the pipe assembly fixture 202 using the second insertion robotic manipulator 610. In another example, the plurality of transfer robotic manipulators 602 between the first termination end 306 of the wire harness 300 and the second termination end 308 of the wire harness 300 are spaced a predetermined distance along the upper surface 212 of the tool support structure 214. In still further examples, the predetermined distance includes about one foot to about three feet, about 1.5 feet to about 2.5 feet, about two feet, or any other suitable distance.

[0098] In yet another example of the method 1400, the picking 1408 of the harness 300 and the placing 1410 of the harness 300 include picking 2702 using the robotic manipulator 218 disposed on the upper surface 212 of the tool support structure 214 (see FIG. Figure 27 ) The wire harness 300 between the first termination end 306 and the second termination end 308. At 2704, the wire harness 300 between the first termination end 306 and the second termination end 308 is placed in the wire harness routing supports 514, 522 of the predetermined longitudinal routing channel 516 in the pipe assembly fixture 202 using the robotic manipulator 218. In another example, the picking up 1408 of the wire harness 300 and the placing 1410 of the wire harness 300 also include moving 2802 toward the first shuttle 210 (see Figure 28 ) The robotic manipulator 218 on the robotic transfer unit 608, 612. The robotic manipulator 218 is mounted on the robotic transfer unit 608, 612. The robotic transfer unit 608, 612 is disposed on the upper surface 212 of the tool support structure 214. At 2804, the first termination end 306 of the wire harness 300 is picked up from the first shuttle 210 using the robotic manipulator 218. At 2806, the first termination end 306 of the wire harness 300 is placed in a predetermined starting electrical connector 512, 518 in the pipe assembly fixture 202 using the robotic manipulator 218. In a further example, the picking up 1408 of the wire harness 300 and the placing 1410 of the wire harness 300 also include moving 2902 toward the second shuttle 216 (see Figure 29 ) The robotic manipulator 218 on the robotic transfer unit 608, 612. At 2904, the second termination end 308 of the wire harness 300 is picked up from the second shuttle 216 using the robotic manipulator 218. At 2906, the second termination end 308 of the wire harness 300 is placed in the intended target electrical connector 512, 518 in the conduit assembly fixture 202 using the robotic manipulator 218.

[0099] Overall reference Figures 1 to 7 and Figures 30 to 36 , as an example, the present disclosure relates to a method 3000 for assembling an electrical conduit module. Figure 1 An example of a manufacturing system for assembling a wire harness 300 , a conduit assembly fixture 202 , and an electrical conduit module is shown. Figure 2 An example of a wire harness assembly system 100 for assembling an electrical conduit module is shown. Figure 3 An example of a wire harness 300 is shown. Figure 4 Shown for transport Figure 3 1 and 2. An example of a wire harness carrier 400 of the wire harness 300 is shown. Figure 5 Shown Figure 2 1. An example of a conduit assembly fixture 202 of the wire harness assembly system 100. Figure 6 Another example of a wire harness assembly system 100 for assembling an electrical conduit module is shown. Figure 7 Shown Figure 6 An example of a harness shuttle subsystem 208 of the harness assembly system 100 is shown.

[0100] Figure 30 An example of a method 3000 for assembling an electrical conduit module is provided. Figure 31 Provided in Figure 30 An example of receiving 3002 of the pipe assembly fixture 202 in the method 3000 is shown. Figure 32 Provided in Figure 30 An example of receiving 3004 of the harness 300 in the method 3000 . Figure 33 Provided in Figure 30 An example of positioning 3006 of wire harness 300 in method 3000 . Figure 34 Provided in Figure 30 An example of picking 3008 of the wire harness 300 in the method 3000 . Figure 35 Provided in Figure 30 An example of placement 3010 of wire harness 300 in method 3000 . Figure 36 Provided in Figure 30 Another example of picking 3008 and placing 3010 of the wire harness 300 in the method 3000 is shown.

[0101] Reference again Figures 1 to 7and Figures 30 to 36 In one or more examples, a method 3000 for assembling an electrical conduit module (see Figure 30 ) includes receiving 3002 a conduit assembly fixture 202 from the conduit preparation area 106 on a workpiece support structure 206. The workpiece support structure 206 is adjacent to the tool support structure 214. At 3004, a wire harness 300 is received from the harness preparation system 102 for placement in the conduit assembly fixture 202. The wire harness 300 includes a first termination end 306 and a second termination end 308. At 3006, the wire harness 300 is positioned on the upper surface 212 of the tool support structure 214 between a first shuttle 210 holding the first termination end 306 and a second shuttle 216 holding the second termination end 308. At 3008, the wire harness 300 having the first termination end 306 and the second termination end 308 is picked up from the upper surface 212 of the tool support structure 214. The first shuttle 210 and the second shuttle 216 are positioned. At 3010, the wire harness 300 is placed at a predetermined location in the conduit assembly fixture 202. At 3012, the receiving 3002, 3004, positioning 3006, picking 3008, and placing 3010 of the wire harness 300 are repeated for the next wire harness 300 until all wire harnesses designated for autonomous placement in the conduit assembly fixture 202 are placed. At 3104, the conduit assembly fixture 202 is transferred to the post-harness assembly area 108 for a manual assembly process on the conduit assembly fixture 202 to prepare the electrical conduit module for installation in the final product.

[0102] In another example of the method 3000, receiving 3002 the pipe assembly fixture 202 includes receiving 3102 the pipe assembly fixture 202 from the pipe preparation area 106 via the pipe delivery system (see FIG. Figure 31 ) The pipe assembly fixture 202. At 3104, the pipe assembly fixture 202 is transferred from the pipe delivery system to the top surface 204 of the workpiece support structure 206. At 3106, the workpiece support structure 206 with the pipe assembly fixture 202 is positioned next to the tool support structure 214. At 3108, the workpiece support structure 206 is locked in place.

[0103] In yet another example of the method 3000, receiving 3004 the wire harness 300 includes picking 3202 from the wire harness carrier 400 on the wire harness delivery system 104 using an auxiliary handling robotic manipulator 614 mounted on a support platform 616 adjacent to a proximal region 618 of the tool support structure 214 (see Figure 32) The coil 302 of the wire harness 300 having the first termination end 306 and the second termination end 308. At 3204, the coil 302, the first termination end 306, and the second termination end 308 are placed on the decoiler assembly 712 disposed on the upper surface 212 at the proximal region 618 of the tool support structure 214 using the auxiliary operation robotic manipulator 614.

[0104] In yet another example of the method 3000, a coil 302 of a wire harness 300 having a first termination end 306 and a second termination end 308 is positioned at the uncoiler assembly 712 located on the upper surface 212 at the proximal region 618 of the tool support structure 214. In this example, positioning 3006 of the wire harness 300 includes capturing 3302 from a wire carrier identification element 408 on a wire carrier 400 of the wire transport system 104 (see Figure 33 ) identification number. The identification number uniquely identifies the wire harness carrier 400 relative to other wire harness carriers on the wire harness delivery system 104. The identification number is correlated to a unique harness number associated with the wire harness 300 and the other wire harnesses of the electrical conduit module. At 3304, a location in the conduit assembly fixture 202 for placement of the wire harness 300, the first termination end 306 of the wire harness 300, and the second termination end 308 of the wire harness 300 is determined based at least in part on the identification number. At 3306, the first shuttle 210 is moved along the first longitudinal track 706 to a first pick position proximate to the uncoiler assembly 712. At 3308, the first termination end 306 of the wire harness 300 is placed in the first shuttle 210 using an auxiliary operation robotic manipulator 614 mounted on a support platform 616 adjacent to the proximal region 618 of the tool support structure 214. At 3310, the first shuttle 210 with the first termination end 306 is moved away from the uncoiler assembly 712, and the rotatable plate 718 of the uncoiler assembly 712 is rotated until the coil 302 of the wire harness 300 is completely unwound. At 3312, the second shuttle 216 is moved along the second longitudinal track 710 to a second pick-up position adjacent to the uncoiler assembly 712. At 3314, the second termination end 308 of the wire harness 300 is placed from the second end holder 722 on the uncoiler assembly 712 into the second shuttle 216 using the auxiliary operation robotic manipulator 614. At 3316, the first shuttle 210 with the first termination end 306 and the second shuttle 216 with the second termination end 308 are moved away from the uncoiler assembly 712 until the wire harness 300 is positioned adjacent to the target location for the wire harness 300 in the conduit assembly fixture 202.

[0105] In yet another example of the method 3000, picking up 3008 the harness 300 includes moving 3402 toward the first shuttle 210 (see Figure 34) A first insertion robotic manipulator 606 on a first robotic transfer unit 608 is moved. The first insertion robotic manipulator 606 is mounted on the first robotic transfer unit 608. The first robotic transfer unit 608 is disposed on the upper surface 212 of the tool support structure 214. At 3404, the first termination end 306 of the wire harness 300 is picked up from the first shuttle 210 using the first insertion robotic manipulator 606. At 3406, a second insertion robotic manipulator 610 on a second robotic transfer unit 612 is moved toward the second shuttle 216. The second insertion robotic manipulator 610 is mounted on the second robotic transfer unit 612. The second robotic transfer unit 612 is disposed adjacent to the first robotic transfer unit 608 on the upper surface 212 of the tool support structure 214. At 3408, the second termination end 308 of the wire harness 300 is picked up from the second shuttle 216 using the second insertion robotic manipulator 610. At 3410 , the wire harness 300 between the first and second termination ends 306 , 308 is picked up using at least one transfer robotic manipulator 602 mounted on the upper surface 212 of the tool support structure 214 adjacent to the first or second robotic transfer unit 608 , 612 .

[0106] In another example of the method 3000, placing 3010 the wire harness 300 includes placing 3502 the wire harness 300 between the first termination end 306 and the second termination end 308 using at least one transfer robotic manipulator 602 mounted adjacent to the upper surface 212 of the tool support structure 214 with either a first robotic transfer unit 608 associated with the first insertion robotic manipulator 606 or a second robotic transfer unit 612 associated with the second insertion robotic manipulator 610 (see FIG. Figure 35 ) in the wire harness routing supports 514, 522 of the predetermined longitudinal routing channel 516 in the pipe assembly fixture 202. The first insertion robotic manipulator 606 is mounted on the first robotic transfer unit 608. The first robotic transfer unit 608 is disposed on the upper surface 212 of the tool support structure 214. The second insertion robotic manipulator 610 is mounted on the second robotic transfer unit 612. The second robotic transfer unit 612 is disposed on the upper surface 212 of the tool support structure 214. At 3504, the first termination end 306 of the wire harness 300 is placed in the predetermined starting electrical connector 512, 518 in the pipe assembly fixture 202 using the first insertion robotic manipulator 606. At 3506, the second termination end 308 of the wire harness 300 is placed in the predetermined target electrical connector 512, 518 in the pipe assembly fixture 202 using the second insertion robotic manipulator 610.

[0107] In yet another example of the method 3000, picking up 3008 of the harness 300 and placing 3010 of the harness 300 include picking up 3602 of the harness 300 using the robotic manipulator 218 disposed on the upper surface 212 of the tool support structure 214 (see FIG. Figure 36 ) The wiring harness 300 between the first termination end 306 and the second termination end 308. At 3604, the wiring harness 300 between the first termination end 306 and the second termination end 308 is placed in the wiring harness routing support 514, 522 of the predetermined longitudinal routing channel 516 in the pipe assembly fixture 202 using the robotic manipulator 218. At 3606, the robotic manipulator 218 on the robotic transfer unit 608, 612 is moved toward the first shuttle 210. The robotic manipulator 218 is mounted on the robotic transfer unit 608, 612. The robotic transfer unit 608, 612 is disposed on the upper surface 212 of the tool support structure 214. At 3608, the first termination end 306 of the wiring harness 300 is picked up from the first shuttle 210 using the robotic manipulator 218. At 3610, the robotic manipulator 218 is used to place the first termination end 306 of the wire harness 300 in the predetermined starting electrical connector 512 in the pipe assembly fixture 202. At 3612, the robotic manipulator 218 on the robotic transfer unit 608, 612 is moved toward the second shuttle 216. At 3614, the robotic manipulator 218 is used to pick up the second termination end 308 of the wire harness 300 from the second shuttle 216. At 3616, the robotic manipulator 218 is used to place the second termination end 308 of the wire harness 300 in the predetermined target electrical connector 512 in the pipe assembly fixture 202.

[0108] Examples of the harness assembly system 100 and methods 1400, 1500, 3000 for assembling electrical conduit modules may be related to or used in the context of aircraft manufacturing. Although an aircraft example is described, the examples and principles disclosed herein may be applied to other products in the aerospace industry and other industries, such as the automotive industry, the space industry, the construction industry, and other design and manufacturing industries. Thus, in addition to aircraft, the examples and principles disclosed herein may be applied to the use of various products in the manufacture of various types of vehicles and the construction of various types of buildings.

[0109] The foregoing detailed description refers to the accompanying drawings, which illustrate specific examples described in the present disclosure. Other examples with different structures and operations do not depart from the scope of the present disclosure. In different drawings, the same reference numerals may refer to the same features, elements or parts. Throughout this disclosure, any one of a plurality of projects may be individually referred to as a project, and a plurality of projects may be collectively referred to as projects and may be referred to with the same reference numerals. In addition, as used herein, features, elements, parts or steps preceded by the word "one" or "an" should be understood as not excluding a plurality of features, elements, parts or steps, unless such exclusion is explicitly stated.

[0110] The above provides illustrative, non-exhaustive examples of the subject matter according to the present disclosure that may be, but not necessarily be, claimed. Reference herein to an "example" means that one or more features, structures, elements, components, characteristics, and / or operational steps described in conjunction with the example are included in at least one aspect, embodiment, and / or implementation of the subject matter according to the present disclosure. Therefore, throughout this disclosure, the phrases "example," "another example," "one or more examples," and similar language may, but do not necessarily, refer to the same example. In addition, the subject matter representing any one example may, but does not necessarily, include the subject matter representing any other example. In addition, the subject matter representing any one example may, but does not necessarily, be combined with the subject matter representing any other example.

[0111] As used herein, a system, device, equipment, structure, article, element, component, or hardware that is “configured to” perform a specified function is actually capable of performing the specified function without any changes, rather than merely having the potential to perform the specified function after further modification. In other words, a system, device, equipment, structure, article, element, component, or hardware that is “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and / or designed for the purpose of performing the specified function. As used herein, “configured to” means an existing characteristic of a system, device, structure, article, element, component, or hardware that enables the system, device, structure, article, element, component, or hardware to perform the specified function without further modification. For the purposes of this disclosure, a system, device, equipment, structure, article, element, component, or hardware that is described as “configured to” perform a particular function may additionally or alternatively be described as “adapted to” and / or “operable to” perform that function.

[0112] Unless otherwise indicated, the terms "first," "second," "third," etc., are used herein merely as labels and are not intended to impose order, position, or hierarchical requirements on the items to which these terms refer. Furthermore, reference to, for example, a "second" item does not require or preclude the presence of, for example, a "first" or lower-numbered item and / or, for example, a "third" or higher-numbered item.

[0113] As used herein, the phrase "at least one of" when used with a list of items means that different combinations of one or more of the listed items may be used, and only one of each item in the list may be required. For example, "at least one of Item A, Item B, and Item C" may include, but is not limited to, Item A or Item A and Item B. This example may also include Item A, Item B, and Item C or Item B and Item C. In other examples, "at least one of" may be, for example, but not limited to, two of Item A, one of Item B, and ten of Item C; four of Item B and seven of Item C; and other suitable combinations. As used herein, the term "and / or" and the " / " symbol include any and all combinations of one or more of the associated listed items.

[0114] As used herein, the terms "coupled," "coupled," and similar terms refer to two or more elements that are joined, linked, fastened, attached, connected, communicated, or otherwise associated (e.g., mechanically, electrically, fluidically, optically, electromagnetically) with each other. In various examples, elements can be associated directly or indirectly. As an example, element A can be directly associated with element B. As another example, element A can be indirectly associated with element B, for example, via another element C. It should be understood that not all associations between the various disclosed elements are necessarily represented. Therefore, there can also be connections other than those depicted in the accompanying drawings.

[0115] As used herein, the term "approximately" refers to or indicates a condition that is close, but not exactly close, to the stated condition, but still performs the desired function or achieves the desired result. As an example, the term "approximately" refers to a condition that is within an acceptable predetermined tolerance or accuracy, such as a condition within 10% of the stated condition. However, the term "approximately" does not exclude a condition that is exactly the stated condition. As used herein, the term "substantially" refers to a condition that is substantially the stated condition that performs the desired function or achieves the desired result.

[0116] mentioned above Figures 1 to 7 middle, Figure 8A 、 Figure 8B 、 Figures 9 to 13 and Figure 21 The numerals may represent functional elements, features, or components thereof and do not necessarily imply any particular structure. Therefore, modifications, additions, and / or omissions may be made to the structures shown. In addition, those skilled in the art will appreciate that the numerals not mentioned above Figures 1 to 7 、 Figure 8A 、 Figure 8B 、 Figures 9 to 13 and Figure 21All elements, features, and / or components described and illustrated in the present disclosure need to be included in every example, and not all elements, features, and / or components described herein need to be depicted in every illustrative example. Figures 1 to 7 、 Figure 8A 、 Figure 8B 、 Figures 9 to 13 and Figure 21 Some elements, features and / or components described and shown in the drawings may be combined in various ways without necessarily including Figures 1 to 7 、 Figure 8A 、 Figure 8B 、 Figures 9 to 13 and Figure 21 , other drawings and / or the accompanying disclosure, even if such combination or combinations are not explicitly indicated herein. Similarly, additional features not limited to the examples presented may be combined with some or all of the features shown and described herein. Unless expressly stated otherwise, the above-mentioned Figures 1 to 7 、 Figure 8A 、 Figure 8B 、 Figures 9 to 13 and Figure 21 The schematic diagrams of the examples depicted in the drawings are not meant to imply structural limitations with respect to the illustrative examples. On the contrary, although an illustrative structure is indicated, it should be understood that the structure can be modified as appropriate. Thus, modifications, additions, and / or omissions may be made to the illustrated structure. Furthermore, elements, features, and / or components serving similar or at least substantially similar purposes may be incorporated herein. Figures 1 to 7 、 Figure 8A 、 Figure 8B 、 Figures 9 to 13 and Figure 21 Each of the components is labeled with the same numerals, and such elements, features and / or components may not be referenced herein. Figures 1 to 7 、 Figure 8A 、 Figure 8B 、 Figures 9 to 13 and Figure 21 Similarly, all elements, features and / or components may not be present in Figures 1 to 7 、 Figure 8A 、 Figure 8B 、 Figures 9 to 13 and Figure 21 Each of the EMBODIMENTS is labeled in , but for consistency, the reference numerals associated therewith may be utilized herein.

[0117] In the above mentioned Figures 14 to 36 In the disclosure, the boxes may represent operations, steps, and / or parts thereof, and the lines connecting the boxes do not imply any particular order or dependency between the operations or parts thereof. It should be understood that not all dependencies between the various disclosed operations are necessarily represented. Figures 14 to 36The attached disclosures describing the operations of the disclosed methods set forth herein should not be construed as necessarily determining the order in which the operations must be performed. On the contrary, although an illustrative order is indicated, it should be understood that the order of the operations can be modified when appropriate. Therefore, the operations shown can be modified, added to, and / or omitted, and certain operations can be performed in different orders or simultaneously. In addition, those skilled in the art will appreciate that it is not necessary to perform all the operations described.

[0118] Furthermore, references throughout this specification to features, advantages, or similar language used herein do not imply that all features and advantages that can be achieved with the examples disclosed herein should be or are in any single example. Rather, language referring to features and advantages is understood to mean that a particular feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, discussions of features, advantages, and similar language used throughout this disclosure may, but do not necessarily, refer to the same example.

[0119] Examples of the subject matter disclosed herein can be found in Figure 37 Aircraft manufacturing and service method 3700 as shown and as Figure 38 3700 is described in the context of the aircraft 3800 shown. In one or more examples, the disclosed harness assembly system 100 and methods 1400, 1500, 3000 for assembling electrical conduit modules can be used in aircraft manufacturing. During pre-production, maintenance method 3700 can include specification and design of aircraft 3800 (block 3702) and material procurement (block 3704). During production, component and subassembly manufacturing (block 3706) and system integration (block 3708) of aircraft 3800 can be performed. Thereafter, aircraft 3800 can undergo certification and delivery (block 3710) to enter service (block 3712). While in service, aircraft 3800 can be scheduled for routine maintenance and servicing (block 3714). Routine maintenance and servicing can include modification, reconfiguration, refurbishment, etc. of one or more systems of aircraft 3800.

[0120] Each of the processes of maintenance method 3700 may be performed or carried out by a system integrator, a third party, and / or an operator (e.g., a customer). For purposes of this description, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may include, but is not limited to, an airline, a leasing company, a military entity, a service organization, etc.

[0121] like Figure 38As shown, aircraft 3800 produced by maintenance method 3700 may include airframe 3802 having multiple high-level systems 3804 and interior 3806. Examples of high-level systems 3804 include one or more of propulsion system 3808, electrical system 3810, hydraulic system 3812, and environmental system 3814. Any number of other systems may be included. Although an aerospace example is shown, the principles disclosed herein may be applied to other industries, such as the automotive industry. Thus, in addition to aircraft 3800, the principles disclosed herein may be applied to other vehicles, such as land vehicles, marine vehicles, spacecraft, and the like.

[0122] The disclosed harness assembly system 100 and methods 1400, 1500, 3000 for assembling electrical conduit modules may be employed during any one or more stages of the manufacturing and maintenance method 3700. For example, components or subassemblies corresponding to component and subassembly manufacturing (block 3706) may be manufactured or produced in a manner similar to components or subassemblies produced while the aircraft 3800 is in service (block 3712). Furthermore, one or more examples of the system, method, or combination thereof may be utilized during the production phase (blocks 3706 and 3708), for example, by significantly accelerating assembly of the aircraft 3800 or reducing the cost of the aircraft 3800. Similarly, for example, but not limitation, one or more examples of the system or method implementations or combination thereof may be utilized while the aircraft 3800 is in service (block 3712) and / or during maintenance and service (block 3714).

[0123] The present disclosure is directed to non-limiting embodiments defined in the following terms.

[0124] Clause 1. A wire harness assembly system 100 for assembling an electrical conduit module, the wire harness assembly system comprising:

[0125] a pipe assembly fixture 202 disposed on a top surface 204 of a workpiece support structure 206;

[0126] a harness shuttle subsystem 208 comprising a first shuttle 210 disposed on an upper surface 212 of a tool support structure 214 and a second shuttle 216 disposed on the upper surface 212 ;

[0127] at least one robotic manipulator 218 disposed on the upper surface 212 of the tool support structure 214 ; and

[0128] A system controller 220 is in operative communication with the harness shuttle subsystem 208 and the at least one robotic manipulator 218 to control placement of the harness 300 from the first shuttle 210 and the second shuttle 216 to the tube assembly fixture 202 .

[0129] Clause 2. The wire harness assembly system of clause 1, wherein the electrical conduit module is configured to be installed in an end product as a modular component of an electrical conduit architecture for the end product.

[0130] Clause 3. The wire harness assembly system of clause 2, wherein the end product comprises at least one of an aircraft, a rotorcraft, a bus, a passenger transport vehicle, a military transport vehicle, a combat military vehicle, a power plant, an unmanned aerial vehicle, a boat, a ferry, a cruise ship, a naval vessel, a commercial building, and a residential building.

[0131] Clause 4. The wire harness assembly system of clause 1, wherein the electrical conduit module is at least one of: about 4 inches wide to about 36 inches wide; about 8 inches wide to about 24 inches wide; and about 14 inches wide to about 18 inches wide.

[0132] Clause 5. The wire harness assembly system of clause 1, wherein the electrical conduit module is at least one of: about 2 feet long to about 100 feet long; about 10 feet long to about 80 feet long; about 20 feet long to about 60 feet long; about 30 feet long to about 50 feet long; and about 40 feet long.

[0133] Clause 6. The wire harness assembly system of Clause 1, wherein the workpiece support structure 206 comprises a transfer table.

[0134] Clause 7. The wire harness assembly system of Clause 6, wherein the transfer station comprises at least one of a moving cart, a work table having rollers on a top side, and a support structure having a conveyor belt.

[0135] Clause 8. A wire harness assembly system according to clause 1, wherein the at least one robotic manipulator 218 includes one or more of at least one robotic arm, at least one 4-axis robotic arm, at least one 6-axis robotic arm, at least one 7-axis robotic arm, at least one selectively compliant joint robotic arm, at least one collaborative robot, at least one electromechanical manipulator, at least one automatic mechanical manipulator, at least one semi-automatic mechanical manipulator, at least one fixed actuator assisted operation robot and at least one semi-manual use robot.

[0136] Clause 9. The wire harness assembly system of clause 1, wherein the wire harness assembly system 100 is configured to receive the wire harness 300 on a wire harness carrier 400 from a wire harness preparation system 102 via a wire harness delivery system 104 .

[0137] Clause 10. The wire harness assembly system of clause 9, wherein the wire carrier 400 comprises at least one coil holder 402 , a first end gripper 404 , a second end gripper 406 , and a wire carrier identification element 408 .

[0138] Clause 11. The wire harness assembly system of clause 10, wherein the wire harness carrier identification element 408 comprises at least one of a serial number, a bar code, a machine-readable code, a quick response code, a glyph code, a radio frequency identification tag, and a radio frequency identification label.

[0139] Item 12. A wire harness assembly system according to Item 9, wherein, when received, the wire harness 300 includes a coil 302 having a disconnection point 304, at which the first termination end 306 of the wire harness 300 and the second termination end 308 of the wire harness 300 are separated from the coil 302, and the wire harness 300 also includes a first wire harness marker 310 near the first termination end 306 and a second wire harness marker 312 near the second termination end 308.

[0140] Clause 13. The wire harness assembly system of clause 9, wherein the wire harness 300 comprises at least one of a single conductor, a twisted pair conductor, a multi-conductor cable, a shielded cable, an unjacketed cable, a coaxial cable, an impedance-matched cable, and a fiber optic cable.

[0141] Clause 14. The wire harness assembly system of clause 1, wherein the conduit assembly fixture 202 comprises:

[0142] a duct frame 502 comprising longitudinal side panels 504 , transverse end panels 506 , longitudinal support members 508 between the transverse end panels 506 , and transverse support members 510 between the longitudinal side panels 504 ;

[0143] an electrical connector 512 disposed proximate to the transverse end plate 506; and

[0144] A wire harness routing support 514 is mounted on the lateral support member 510 to define a longitudinal routing channel 516 .

[0145] Clause 15. The wire harness assembly system of clause 14, wherein the electrical connector 512 comprises at least one of a modular connector and a standard connector.

[0146] Clause 16. The wire harness assembly system according to clause 14, wherein the pipe assembly fixture 202 further comprises:

[0147] at least one additional electrical connector 518 disposed proximate to at least one of the longitudinal side panels 504;

[0148] at least one printed wiring board 520 mounted on at least one of the one or more longitudinal side panels 504, one or more transverse end panels 506, one or more longitudinal support members 508, and one or more transverse support members 510; and

[0149] A branch wiring support 522 is installed on the transverse supporting member 510 to define a transverse wiring channel 524 branching from one or more longitudinal wiring channels of the longitudinal wiring channels 516 .

[0150] Clause 17. The wire harness assembly system of clause 1, wherein the first shuttle 210 is configured to receive and temporarily hold the first termination end 306 of the wire harness 300, and the second shuttle 216 is configured to receive and temporarily hold the second termination end 308 of the wire harness 300, and

[0151] The system controller 220 and the harness shuttle subsystem 208 are configured to position the first shuttle 210 and the second shuttle 216 to extend the harness 300 longitudinally over the upper surface 212 of the tool support structure 214 .

[0152] Item 18. A wire harness assembly system according to Item 17, wherein the system controller 220, the wire harness shuttle subsystem 208 and the at least one robotic manipulator 218 are configured to place the wire harness 300 having the first termination end 306 and the second termination end 308 at a predetermined position in the pipe assembly fixture 202.

[0153] Clause 19. The wire harness assembly system of clause 17, wherein the at least one robotic manipulator 218 comprises:

[0154] At least one transfer robotic manipulator 602 is mounted on the upper surface 212 of the tool support structure 214, and the at least one transfer robotic manipulator 602 is configured to pick up the wiring harness 300 from between the first shuttle 210 and the second shuttle 216 and place the wiring harness 300 in one or more wiring harness routing supports 514 at predetermined positions in the pipe assembly fixture 202.

[0155] Clause 20. The wire harness assembly system of clause 19, wherein the at least one transfer robotic manipulator 602 comprises one or more of at least one robotic arm, at least one selectively compliant articulated robotic arm, and at least one collaborative robot.

[0156] Clause 21. The wire harness assembly system of clause 19, wherein the at least one transfer robotic manipulator 602 comprises a plurality of transfer robotic manipulators 602 longitudinally spaced apart along the upper surface 212 of the tool support structure 214 .

[0157] Clause 22. The wire harness assembly system of clause 21, wherein the plurality of transfer robotic manipulators 602 are spaced at least one of about one foot to about two feet, about two feet to about three feet, and about three feet to about four feet apart.

[0158] Clause 23. The wire harness assembly system of clause 17, wherein the at least one robotic manipulator 218 comprises:

[0159] At least one insertion robotic manipulator 604 is disposed on the upper surface 212 of the tool support structure 214, and the at least one insertion robotic manipulator 604 is configured to pick up the first termination end 306 of the wiring harness 300 from the first shuttle 210 and insert the first termination end 306 into a predetermined starting electrical connector 512 at a first predetermined position in the pipe assembly fixture 202.

[0160] Clause 24. The wire harness assembly system of clause 23, wherein the at least one insertion robotic manipulator 604 comprises one or more of at least one robotic arm, at least one 6-axis robotic arm, at least one 7-axis robotic arm, and at least one collaborative robot.

[0161] Item 25. A wire harness assembly system according to Item 23, wherein the at least one insertion robotic manipulator 604 is configured to pick up the second termination end 308 of the wire harness 300 from the second shuttle 216 and insert the second termination end 308 into a predetermined target electrical connector 512 at a second predetermined position in the pipe assembly fixture 202.

[0162] Clause 26. The wire harness assembly system of clause 17, wherein the at least one robotic manipulator 218 comprises:

[0163] a first insertion robotic manipulator 606 mounted on a first robotic transfer unit 608 disposed on the upper surface 212 of the tool support structure 214 and configured to translate the first insertion robotic manipulator 606 the length of the pipe assembly fixture 202, the first insertion robotic manipulator 606 configured to cooperate with the first robotic transfer unit 608 to pick up the first termination end 306 of the wire harness 300 from the first shuttle 210 and insert the first termination end 306 into a predetermined starting electrical connector 512 at a first predetermined position in the pipe assembly fixture 202; and

[0164] A second insertion robot manipulator 610, the second insertion robot manipulator is mounted on a second robot transfer unit 612, the second robot transfer unit 612 is arranged adjacent to the first robot transfer unit 608 on the upper surface 212, and is configured to translate the second insertion robot manipulator 610 the length of the pipe assembly fixture 202, the second insertion robot manipulator 610 is configured to cooperate with the second robot transfer unit 612 to pick up the second termination end 308 of the wiring harness 300 from the second shuttle 216, and insert the second termination end 308 into the predetermined target electrical connector 512 at a second predetermined position in the pipe assembly fixture 202.

[0165] Clause 27. The wire harness assembly system of clause 1, wherein the wire harness shuttle subsystem 208 further comprises:

[0166] a longitudinal groove 702 disposed on the upper surface 212 of the tool support structure 214 and extending alongside the pipe assembly fixture 202;

[0167] a first conveyor assembly 704 mechanically coupled to the first shuttle 210 to position the first shuttle 210 along a first longitudinal track 706 of the longitudinal groove 702;

[0168] a second conveyor assembly 708 mechanically coupled to the second shuttle 216 to position the second shuttle 216 along a second longitudinal track 710 of the longitudinal groove 702;

[0169] an uncoiler assembly 712 disposed on the upper surface 212 of the tool support structure 214 and configured to hold the coil 302 of the wire harness 300 , the first terminated end 306 of the wire harness 300 , and the second terminated end 308 of the wire harness 300 ;

[0170] an image sensor 714 proximate to the uncoiler assembly 712 and configured to selectively capture images of the first and second terminated ends 306 and 308 and images illustrating a state of the coil 302 on the uncoiler assembly 712 ;

[0171] a wire carrier identification detector 715 proximate to a wire carrier 400 on a wire transport system 104, the wire carrier 400 being configured to transport the wire harness 300 from the wire preparation system 102 to the wire harness assembly system 100, the wire carrier identification detector 715 being configured to selectively capture an identification number from a wire carrier identification element 408 on the wire carrier 400; and

[0172] A control assembly 716 that operatively communicates with the first conveyor assembly 704, the second conveyor assembly 708, the uncoiler assembly 712, the image sensor 714, the harness carrier identification detector 715, and the system controller 220 to control the transfer of the first termination end 306 from the uncoiler assembly 712 to the first shuttle 210, the movement of the first shuttle 210 along the first longitudinal track 706, the unwinding of the coil 302 from the uncoiler assembly 712, the placement of the second termination end 308 from the uncoiler assembly 712 to the second shuttle 216, and the movement of the second shuttle 216 along the second longitudinal track 710.

[0173] Clause 28. The wire harness assembly system of clause 27, wherein the first conveyor assembly 704 comprises at least one of a stepper motor, a DC motor, an encoder device, a position sensor, a belt drive assembly, a screw drive assembly, and a chain drive assembly.

[0174] Clause 29. The wire harness assembly system of clause 27, wherein the second conveyor assembly 708 comprises at least one of a stepper motor, a DC motor, an encoder device, a position sensor, a belt drive assembly, a screw drive assembly, and a chain drive assembly.

[0175] Clause 30. The wire harness assembly system of clause 27, wherein the image sensor 714 comprises at least one of a digital camera, a charge coupled device, an active pixel device, an optical scanner, and a laser scanner.

[0176] Clause 31. The wire harness assembly system of clause 27, wherein the wire harness carrier identification detector 715 comprises at least one of a digital camera, a charge coupled device, an active pixel device, an optical scanner, a laser scanner, a radio frequency identification reader, and a radio frequency identification transponder.

[0177] Clause 32. The wire harness assembly system of clause 27, wherein the uncoiler assembly 712 comprises:

[0178] a rotatable plate 718 configured to temporarily hold the coil 302 of the harness 300 and unwind the harness 300 in response to tension on the first termination end 306 in conjunction with movement of the first shuttle 210 along the first longitudinal track 706 of the harness shuttle subsystem 208;

[0179] a first end retainer 720 disposed proximate the rotatable plate 718 and configured to temporarily retain the first terminating end 306 of the wire harness 300 ; and

[0180] A second end retainer 722 is mounted on the rotatable plate 718 and is configured to retain the second terminating end 308 of the wire harness 300 .

[0181] Clause 33. The wire harness assembly system of clause 32, wherein the first end retainer 720 comprises the first shuttle 210 proximate the rotatable plate 718 when positioned on the first longitudinal track 706 of the longitudinal groove 702.

[0182] Clause 34. The wire harness assembly system of clause 32, further comprising:

[0183] An auxiliary operation robotic manipulator 614 is mounted on a support platform 616 adjacent to a proximal region 618 of the tool support structure 214, the auxiliary operation robotic manipulator 614 being configured to pick up the coil 302, the first termination end 306 and the second termination end 308 of the wire harness 300 from the wire harness carrier 400 on the wire harness conveying system 104, and place the coil 302 on the rotatable plate 718 of the uncoiler assembly 712, place the first termination end 306 on the first end retainer 720, and place the second termination end 308 on the second end retainer 722.

[0184] Clause 35. A wire harness assembly system according to clause 34, wherein the auxiliary operation robot manipulator 614 includes at least one of a robotic arm, a 6-axis robotic arm, a collaborative robot, an electromechanical manipulator, an automatic mechanical manipulator, a semi-automatic mechanical manipulator, a fixed actuator auxiliary operation robot and a semi-manual use robot.

[0185] Clause 36. The wire harness assembly system of clause 34, wherein the system controller 220 and the auxiliary operation robotic manipulator 614 are configured to pick up the first termination end 306 of the wire harness 300 from the first end holder 720 and place the first termination end 306 on the first shuttle 210, and

[0186] In which, the system controller 220 and the auxiliary operation robot manipulator 614 are configured to pick up the second termination end 308 of the wiring harness 300 from the second end retainer 722 and place the second termination end 308 on the second shuttle 216 after the system controller 220 detects that the wiring harness 300 is unwound from the rotatable plate 718.

[0187] Clause 37. A method 1400 for assembling an electrical conduit module, the method comprising:

[0188] receiving 1402 the pipe assembly fixture 202 from the pipe preparation area 106 on a workpiece support structure 206 that is adjacent to the tool support structure 214 ;

[0189] receiving 1404 a wire harness 300 from a wire harness preparation system 102 for placement in the conduit assembly fixture 202 , the wire harness 300 including a first termination end 306 and a second termination end 308 ;

[0190] Positioning 1406 the harness 300 on the upper surface 212 of the tool support structure 214 between the first shuttle 210 holding the first termination end 306 and the second shuttle 216 holding the second termination end 308 ;

[0191] picking up 1408 the wire harness 300 having the first terminating end 306 and the second terminating end 308 from the upper surface 212 of the tool support structure 214 , the first shuttle 210 , and the second shuttle 216 ; and

[0192] The wire harness 300 is placed 1410 at a predetermined location in the duct assembly fixture 202 .

[0193] Clause 38. The method of Clause 37, wherein the electrical conduit module is configured to be installed in a final product as a modular component of an electrical conduit architecture for the final product.

[0194] Clause 39. The method of clause 38, wherein the final product comprises at least one of an aircraft, a rotorcraft, an unmanned aerial vehicle, a bus, a passenger transport vehicle, a military transport vehicle, a combat military vehicle, a passenger ship, a cargo ship, a warship, a commercial building, and a residential building.

[0195] Clause 40. The method of Clause 37, wherein the electrical conduit module is at least one of: about 4 inches wide to about 36 inches wide; about 8 inches wide to about 24 inches wide; and about 14 inches wide to about 18 inches wide.

[0196] Clause 41. The method of clause 37, wherein the electrical conduit module is at least one of: about 2 feet long to about 100 feet long; about 10 feet long to about 80 feet long; about 20 feet long to about 60 feet long; about 30 feet long to about 50 feet long; and about 40 feet long.

[0197] Clause 42. The method of Clause 37, wherein the workpiece support structure 206 comprises a transfer table.

[0198] Clause 43. The method of Clause 42, wherein the transfer station comprises at least one of a moving cart, a work table having rollers on a top side, and a support structure having a conveyor belt.

[0199] Clause 44. The method of clause 37, wherein the method is implemented in a wire harness assembly system 100 configured to receive the wire harness 300 on a wire harness carrier 400 from a wire harness preparation system 102 via a wire harness delivery system 104 .

[0200] Clause 45. A method according to clause 44, wherein, when received, the wiring harness 300 includes a coil 302 having a disconnection point 304, at which the first termination end 306 of the wiring harness 300 and the second termination end 308 of the wiring harness 300 are separated from the coil 302, and the wiring harness 300 also includes a first wiring harness marker 310 near the first termination end 306 and a second wiring harness marker 312 near the second termination end 308.

[0201] Clause 46. The method of clause 44, wherein the wiring harness 300 comprises at least one of a single conductor, a twisted pair of conductors, a multi-conductor cable, a shielded cable, an unjacketed cable, a coaxial cable, an impedance-matched cable, and a fiber optic cable.

[0202] Clause 47. The method 1500 of clause 37, further comprising:

[0203] The receiving 1402 , 1404 , positioning 1406 , picking 1408 , and placing 1410 of the harness 300 are repeated 1502 for the next harness 300 until all harnesses designated for autonomous placement in the tube assembly fixture 202 are placed.

[0204] Clause 48. The method according to clause 47, further comprising:

[0205] The conduit assembly fixture 202 is transferred 1504 to the rear harness assembly area 108 for a manual assembly process to be performed on the conduit assembly fixture 202 to prepare the electrical conduit module for installation in a final product.

[0206] Clause 49. The method 1400 of clause 37, wherein the receiving 1402 of the pipe assembly fixture 202 comprises:

[0207] receiving 1602 the pipe assembly fixture 202 from the pipe preparation area 106 via a pipe delivery system;

[0208] transferring 1604 the tubing assembly fixture 202 from the tubing delivery system to the top surface 204 of the workpiece support structure 206 ;

[0209] moving 1606 the workpiece support structure 206 with the pipe assembly fixture 202 alongside the tool support structure 214 ; and

[0210] The workpiece support structure 206 is locked 1608 in place.

[0211] Clause 50. The method of clause 37, wherein the receiving 1402 of the pipe assembly fixture 202 comprises:

[0212] transporting 1702 the pipe assembly fixture 202 from the pipe preparation area 106 on the workpiece support structure 206 ;

[0213] moving 1704 the workpiece support structure 206 with the pipe assembly fixture 202 alongside the tool support structure 214 ; and

[0214] The workpiece support structure 206 is locked 1706 in place.

[0215] Clause 51. The method of clause 37, wherein the receiving 1404 of the wiring harness 300 comprises:

[0216] picking up 1802 the coil 302 of the wire harness 300 having the first termination end 306 and the second termination end 308 from the wire harness carrier 400 on the wire harness delivery system 104 using an auxiliary handling robotic manipulator 614 mounted on a support platform 616 adjacent to a proximal region 618 of the tool support structure 214; and

[0217] The coil 302 , the first termination end 306 , and the second termination end 308 are placed 1804 onto the uncoiler assembly 712 disposed on the upper surface 212 at the proximal region 618 of the tool support structure 214 using the auxiliary operation robotic manipulator 614 .

[0218] Clause 52. The method of clause 51, wherein said picking up 1802 of said coil 302 comprises:

[0219] picking up 1902 the coil 302 of the wiring harness 300 from at least one coil holder 402 of the wiring harness carrier 400 using at least one first holding device 2102 attached to the end effector 2100 of the auxiliary operation robotic manipulator 614 ;

[0220] picking up 1904 the first terminating end 306 of the wire harness 300 from the first end gripper 404 of the wire harness carrier 400 using the second holding device 2104 of the end effector 2100 ; and

[0221] The second terminating end 308 of the wire harness 300 is picked up 1906 from the second end gripper 406 of the wire carrier 400 using the third holding device 2106 of the end effector 2100 .

[0222] Clause 53. The method of clause 51, wherein the placing 1804 of the coil 302 comprises:

[0223] placing 2002 the coil 302 of the wire harness 300 from at least one first holding device 2102 of an end effector 2100 attached to the assisted operation robotic manipulator 614 onto the rotatable plate 718 of the uncoiler assembly 712 ;

[0224] placing 2004 the first terminating end 306 of the wire harness 300 from the second retaining device 2104 of the end effector 2100 onto the first end retainer 720 of the uncoiler assembly 712 ; and

[0225] The second terminated end 308 of the wire harness 300 is placed 2006 from the third retaining device 2106 of the end effector 2100 onto the second end retainer 722 of the uncoiler assembly 712 .

[0226] Clause 54. The method of clause 53, wherein the first end retainer 720 comprises the first shuttle 210 proximate the rotatable plate 718 when positioned.

[0227] Clause 55. The method of clause 37, wherein positioning 1406 the coil 302 of the wire harness 300 having the first termination end 306 and the second termination end 308 at the uncoiler assembly 712 located on the upper surface 212 at the proximal region 618 of the tool support structure 214, the positioning 300 comprising:

[0228] capturing 2202 an identification number from a wire carrier identification element 408 on a wire carrier 400 of the wire delivery system 104 , the identification number uniquely identifying the wire carrier 400 relative to other wire carriers on the wire delivery system 104 , the identification number being related to a unique wire harness number associated with the wire harness 300 and other wire harnesses relative to the electrical conduit module;

[0229] determining 2204 a location in the pipe assembly fixture 202 for placing the wire harness 300 , the first terminating end 306 of the wire harness 300 , and the second terminating end 308 of the wire harness 300 based at least in part on the identification number;

[0230] moving 2206 the first shuttle 210 along the first longitudinal track 706 to a first pick-up position proximate to the uncoiler assembly 712 ;

[0231] placing 2208 the first termination end 306 of the harness 300 in the first shuttle 210 using an auxiliary handling robotic manipulator 614 mounted on a support platform 616 adjacent the proximal region 618 of the tool support structure 214;

[0232] Moving 2210 the first shuttle 210 having the first terminating end 306 away from the uncoiler assembly 712 and rotating the rotatable plate 718 of the uncoiler assembly 712 until the coil 302 of the wiring harness 300 is completely unwound;

[0233] moving 2212 the second shuttle 216 along the second longitudinal track 710 to a second pick-up position proximate to the uncoiler assembly 712 ;

[0234] placing 2214 the second terminating end 308 of the harness 300 from the second end holder 722 on the uncoiler assembly 712 in the second shuttle 216 using the auxiliary operation robotic manipulator 614 ; and

[0235] The first shuttle 210 having the first terminating end 306 and the second shuttle 216 having the second terminating end 308 are moved 2216 away from the uncoiler assembly 712 until the wire harness 300 is positioned adjacent to the target location of the wire harness 300 in the conduit assembly fixture 202 .

[0236] Clause 56. The method of clause 55, wherein the moving 2210 of the first shuttle 210 and the rotating of the rotatable plate 718 comprises:

[0237] capturing 2302 a series of visual images of the rotatable plate 718 as the coil 302 of the harness 300 is unwound;

[0238] determining 2304 that the coil 302 of the harness 300 is unwound from the rotatable plate 718 based at least in part on the series of visual images; and

[0239] Once the coil 302 is unwound, the movement 2210 of the first shuttle 210 and the rotation of the rotatable plate 718 are stopped 2306 .

[0240] Clause 57. The method of clause 55, wherein the first shuttle 210 includes a first force sensor 724 and the second shuttle 216 includes a second force sensor 726, the movement 2216 of the first shuttle 210 and the movement of the second shuttle 216 comprising:

[0241] After the wire harness 300 is positioned next to the target location of the wire harness 300 , stopping 2402 the movement 2216 of the first shuttle 210 and the movement of the second shuttle 216 ;

[0242] Slowly moving 2404 the first shuttle 210 away from the target position of the wire harness 300;

[0243] Slowly moving 2406 the second shuttle 216 away from the target position of the wire harness 300 ;

[0244] stopping 2408 the opposing movements of the first and second shuttles 210 and 216 after at least one of the first and second force sensors 724 and 726 detects that the tension on the harness 300 exceeds a predetermined tension threshold; and

[0245] The first and second shuttles 210 and 216 are retracted 2410 a predetermined amount to remove tension and relatively center the first and second terminating ends 306 and 308 of the harness 300 relative to a target position of the harness 300 .

[0246] Clause 58. The method of Clause 57, wherein the predetermined tension threshold comprises at least one of about one pound of tension to about five pounds of tension, about two pounds of tension to about four pounds of tension, and about three pounds of tension.

[0247] Clause 59. A method according to Clause 57, wherein the predetermined retraction amount toward the target position of the wiring harness 300 includes at least one of approximately 0.1% to approximately 0.7% of the length of the wiring harness 300, approximately 0.2% to approximately 0.6% of the length of the wiring harness 300, approximately 0.3% to approximately 0.5% of the length of the wiring harness 300, and approximately 0.4% of the length of the wiring harness 300.

[0248] Clause 60. The method of clause 37, wherein the picking up 1408 of the wire harness 300 comprises:

[0249] moving 2502 a first insertion robotic manipulator 606 on a first robotic transfer unit 608 toward the first shuttle 210 , the first insertion robotic manipulator 606 being mounted on the first robotic transfer unit 608 , the first robotic transfer unit 608 being disposed on the upper surface 212 of the tool support structure 214 ;

[0250] picking 2504 the first terminating end 306 of the wire harness 300 from the first shuttle 210 using the first insertion robotic manipulator 606 ;

[0251] moving 2506 a second insertion robotic manipulator 610 on a second robotic transfer unit 612 toward the second shuttle 216 , the second insertion robotic manipulator 610 being mounted on the second robotic transfer unit 612 , the second robotic transfer unit 612 being disposed on the upper surface 212 of the tool support structure 214 adjacent to the first robotic transfer unit 608 ;

[0252] picking 2508 the second terminating end 308 of the wire harness 300 from the second shuttle 216 using the second insertion robotic manipulator 610 ; and

[0253] The wire harness 300 between the first and second termination ends 306 and 308 is picked up 2510 using at least one transfer robotic manipulator 602 mounted on the upper surface 212 of the tool support structure 214 adjacent to the first or second robotic transfer unit 608 , 612 .

[0254] Clause 61. The method of clause 60, wherein a plurality of transfer robotic manipulators 602 between the first termination end 306 of the wire harness 300 and the second termination end 308 of the wire harness 300 are spaced apart a predetermined distance along the upper surface 212 of the tool support structure 214.

[0255] Clause 62. The method of clause 61, wherein the predetermined distance comprises at least one of approximately one foot to approximately three feet, approximately 1.5 feet to approximately 2.5 feet, and approximately two feet.

[0256] Clause 63. The method of clause 37, wherein the placing 1410 of the wiring harness 300 comprises:

[0257] placing 2602 the wiring harness 300 between the first termination end portion 306 and the second termination end portion 308 in the wiring harness routing support 514 of the predetermined longitudinal routing channel 516 in the pipe assembly fixture 202 using at least one transfer robotic manipulator 602 mounted adjacent to the upper surface 212 of the tool support structure 214, either a first robotic transfer unit 608 associated with a first insertion robotic manipulator 606 or a second robotic transfer unit 612 associated with a second insertion robotic manipulator 610, wherein the first insertion robotic manipulator 606 is mounted on the first robotic transfer unit 608, which is disposed on the upper surface 212 of the tool support structure 214, and the second insertion robotic manipulator 610 is mounted on the second robotic transfer unit 612, which is disposed on the upper surface 212 of the tool support structure 214;

[0258] placing 2604 the first terminating end 306 of the wire harness 300 in a predetermined starting electrical connector 512 in the conduit assembly fixture 202 using the first insertion robotic manipulator 606 ; and

[0259] The second termination end 308 of the wire harness 300 is placed 2606 in the predetermined target electrical connector 512 in the conduit assembly fixture 202 using the second insertion robotic manipulator 610 .

[0260] Clause 64. The method of clause 63, wherein a plurality of transfer robotic manipulators 602 between the first termination end 306 of the wire harness 300 and the second termination end 308 of the wire harness 300 are spaced apart a predetermined distance along the upper surface 212 of the tool support structure 214.

[0261] Clause 65. The method of clause 64, wherein the predetermined distance comprises at least one of approximately one foot to approximately three feet, approximately 1.5 feet to approximately 2.5 feet, and approximately two feet.

[0262] Clause 66. The method of clause 37, wherein the picking up 1408 of the wire harness 300 and the placing 1410 of the wire harness 300 comprise:

[0263] picking up 2702 the wire harness 300 between the first terminating end 306 and the second terminating end 308 using a robotic manipulator 218 disposed on the upper surface 212 of the tool support structure 214 ; and

[0264] The wiring harness 300 between the first termination end 306 and the second termination end 308 is placed 2704 in the wiring harness routing support 514 of the predetermined longitudinal routing channel 516 in the tube assembly fixture 202 using the robotic manipulator 218 .

[0265] Clause 67. The method of clause 66, wherein the picking up 1408 of the wire harness 300 and the placing 1410 of the wire harness 300 further comprise:

[0266] moving 2802 the robotic manipulator 218 on a robotic transfer unit 608 , 612 , the robotic manipulator 218 being mounted on the robotic transfer unit 608 , 612 , disposed on the upper surface 212 of the tool support structure 214 , toward the first shuttle 210 ;

[0267] picking up 2804 the first terminating end 306 of the wire harness 300 from the first shuttle 210 using the robotic manipulator 218 ; and

[0268] The first terminating end 306 of the wire harness 300 is placed 2806 in a predetermined starting electrical connector 512 in the conduit assembly fixture 202 using the robotic manipulator 218 .

[0269] Clause 68. The method of clause 67, wherein the picking up 1408 of the wire harness 300 and the placing 1410 of the wire harness 300 further comprise:

[0270] moving 2902 the robotic manipulator 218 on the robotic transfer unit 608 , 612 toward the second shuttle 216 ;

[0271] picking up 2904 the second terminating end 308 of the wire harness 300 from the second shuttle 216 using the robotic manipulator 218 ; and

[0272] The second terminating end 308 of the wire harness 300 is placed 2906 in the intended target electrical connector 512 in the conduit assembly fixture 202 using the robotic manipulator 218 .

[0273] Clause 69. A method 3000 for assembling an electrical conduit module, the method comprising:

[0274] receiving 3002 the pipe assembly fixture 202 from the pipe preparation area 106 on a workpiece support structure 206 that is adjacent to the tool support structure 214 ;

[0275] receiving 3004 a wire harness 300 from a wire harness preparation system 102 for placement in the conduit assembly fixture 202 , the wire harness 300 including a first termination end 306 and a second termination end 308 ;

[0276] Positioning 1406 the harness 300 on the upper surface 212 of the tool support structure 214 between the first shuttle 210 holding the first termination end 306 and the second shuttle 216 holding the second termination end 308 ;

[0277] picking up 3008 the wire harness 300 having the first terminating end 306 and the second terminating end 308 from the upper surface 212 of the tool support structure 214 , the first shuttle 210 , and the second shuttle 216 ;

[0278] placing 3010 the wiring harness 300 at a predetermined position in the pipe assembly fixture 202 ;

[0279] Repeating 3012 the receiving 3002 , 3004 , positioning 3006 , picking 3008 , and placing 3010 of the harness 300 for the next harness 300 until all harnesses designated for autonomous placement in the tube assembly fixture 202 are placed; and

[0280] The conduit assembly fixture 202 is transferred 3014 to the rear harness assembly area 108 for a manual assembly process to be performed on the conduit assembly fixture 202 to prepare the electrical conduit module for installation in a final product.

[0281] Clause 70. The method of clause 69, wherein the receiving 1402 of the pipe assembly fixture 202 comprises:

[0282] receiving 3102 the pipe assembly fixture 202 from the pipe preparation area 106 via a pipe delivery system;

[0283] transferring 3104 the tube assembly fixture 202 from the tube delivery system to the top surface 204 of the workpiece support structure 206 ;

[0284] moving 3106 the workpiece support structure 206 having the pipe assembly fixture 202 alongside the tool support structure 214; and

[0285] The workpiece support structure 206 is locked 3108 in place.

[0286] Clause 71. The method of clause 69, wherein the receiving 3004 of the wiring harness 300 comprises:

[0287] picking up 3202 the coil 302 of the wire harness 300 having the first termination end 306 and the second termination end 308 from the wire harness carrier 400 on the wire harness delivery system 104 using an auxiliary handling robotic manipulator 614 mounted on a support platform 616 adjacent a proximal region 618 of the tool support structure 214; and

[0288] The coil 302 , the first termination end 306 , and the second termination end 308 are placed 3204 onto the uncoiler assembly 712 disposed on the upper surface 212 at the proximal region 618 of the tool support structure 214 using the auxiliary operation robotic manipulator 614 .

[0289] Clause 72. The method of clause 69, wherein positioning the coil 302 of the wire harness 300 having the first termination end 306 and the second termination end 308 at the uncoiler assembly 712 located on the upper surface 212 at the proximal region 618 of the tool support structure 214, the positioning 3006 of the wire harness 300 comprising:

[0290] capturing 3302 an identification number from a wire carrier identification element 408 on a wire carrier 400 of the wire delivery system 104 , the identification number uniquely identifying the wire carrier 400 relative to other wire carriers on the wire delivery system 104 , the identification number being related to a unique wire harness number associated with the wire harness 300 and other wire harnesses relative to the electrical conduit module;

[0291] determining 3304 a location in the conduit assembly fixture 202 for placing the wire harness 300 , the first terminating end 306 of the wire harness 300 , and the second terminating end 308 of the wire harness 300 based at least in part on the identification number;

[0292] moving 3306 the first shuttle 210 along the first longitudinal track 706 to a first pick position proximate to the uncoiler assembly 712 ;

[0293] placing 2208 the first termination end 306 of the harness 300 in the first shuttle 210 using an auxiliary handling robotic manipulator 614 mounted on a support platform 616 adjacent the proximal region 618 of the tool support structure 214;

[0294] Moving 3310 the first shuttle 210 having the first terminating end 306 away from the uncoiler assembly 712 and rotating the rotatable plate 718 of the uncoiler assembly 712 until the coil 302 of the wire harness 300 is completely unwound;

[0295] moving 3312 the second shuttle 216 along the second longitudinal track 710 to a second pick position proximate to the uncoiler assembly 712 ;

[0296] placing 3314 the second terminated end 308 of the wire harness 300 from the second end holder 722 on the uncoiler assembly 712 into the second shuttle 216 using the auxiliary operation robotic manipulator 614; and

[0297] The first shuttle 210 having the first terminating end 306 and the second shuttle 216 having the second terminating end 308 are moved 3316 away from the uncoiler assembly 712 until the wire harness 300 is positioned adjacent to the target location of the wire harness 300 in the conduit assembly fixture 202 .

[0298] Clause 73. The method of clause 69, wherein said picking up 3008 of said wire harness 300 comprises:

[0299] moving 3402 a first insertion robotic manipulator 606 on a first robotic transfer unit 608 toward the first shuttle 210 , the first insertion robotic manipulator 606 being mounted on the first robotic transfer unit 608 , the first robotic transfer unit 608 being disposed on the upper surface 212 of the tool support structure 214 ;

[0300] picking 3404 the first terminating end 306 of the wire harness 300 from the first shuttle 210 using the first insertion robotic manipulator 606 ;

[0301] moving 2506 a second insertion robotic manipulator 610 on a second robotic transfer unit 612 toward the second shuttle 216 , the second insertion robotic manipulator 610 being mounted on the second robotic transfer unit 612 , the second robotic transfer unit 612 being disposed on the upper surface 212 of the tool support structure 214 adjacent to the first robotic transfer unit 608 ;

[0302] picking up 3408 the second terminating end 308 of the wire harness 300 from the second shuttle 216 using the second insertion robotic manipulator 610 ; and

[0303] The wire harness 300 between the first and second termination ends 306 and 308 is picked up 2510 using at least one transfer robotic manipulator 602 mounted on the upper surface 212 of the tool support structure 214 adjacent to the first or second robotic transfer unit 608 , 612 .

[0304] Clause 74. The method of clause 69, wherein the placing 3010 of the wiring harness 300 comprises:

[0305] placing 3502 the wire harness 300 between the first termination end portion 306 and the second termination end portion 308 in the wire harness routing support 514 of the predetermined longitudinal routing channel 516 in the pipe assembly fixture 202 using at least one transfer robotic manipulator 602 mounted adjacent to the upper surface 212 of the tool support structure 214 and associated with a first robotic transfer unit 608 associated with a first insertion robotic manipulator 606 or a second robotic transfer unit 612 associated with a second insertion robotic manipulator 610, wherein the first insertion robotic manipulator 606 is mounted on the first robotic transfer unit 608 and the first robotic transfer unit 608 is disposed on the upper surface 212 of the tool support structure 214, and the second robotic insertion manipulator 610 is mounted on the second robotic transfer unit 612 and the second robotic transfer unit 612 is disposed on the upper surface 212 of the tool support structure 214;

[0306] placing 3504 the first terminating end 306 of the wire harness 300 in a predetermined starting electrical connector 512 in the conduit assembly fixture 202 using the first insertion robotic manipulator 606 ; and

[0307] The second termination end 308 of the wire harness 300 is placed 3506 in the predetermined target electrical connector 512 in the conduit assembly fixture 202 using the second insertion robotic manipulator 610 .

[0308] Clause 75. The method of clause 69, wherein the picking up 3008 of the wire harness 300 and the placing 3010 of the wire harness 300 comprise:

[0309] picking up 3602 the wire harness 300 between the first termination end 306 and the second termination end 308 using a robotic manipulator 218 disposed on the upper surface 212 of the tool support structure 214 ;

[0310] using the robotic manipulator 218 to place 3604 the wire harness 300 between the first termination end 306 and the second termination end 308 in a wire harness routing support 514 of a predetermined longitudinal routing channel 516 in the pipe assembly fixture 202 ;

[0311] moving 3606 the robotic manipulator 218 on a robotic transfer unit 608 , 612 , the robotic manipulator 218 being mounted on the robotic transfer unit 608 , 612 , the robotic transfer unit 608 , 612 being disposed on the upper surface 212 of the tool support structure 214 , toward the first shuttle 210 ;

[0312] picking up 3608 the first terminating end 306 of the wire harness 300 from the first shuttle 210 using the robotic manipulator 218 ;

[0313] using the robotic manipulator 218 to place 3610 the first terminating end 306 of the wiring harness 300 in a predetermined starting electrical connector 512 in the conduit assembly fixture 202 ;

[0314] moving 3612 the robotic manipulator 218 on the robotic transfer unit 608 , 612 toward the second shuttle 216 ;

[0315] picking up 3614 the second terminating end 308 of the wire harness 300 from the second shuttle 216 using the robotic manipulator 218 ; and

[0316] The second termination end 308 of the wire harness 300 is placed 3616 in the intended target electrical connector 512 in the conduit assembly fixture 202 using the robotic manipulator 218 .

[0317] The described features, advantages, and characteristics of one example may be combined in any suitable manner in one or more other examples. Those skilled in the relevant art will recognize that the examples described herein may be practiced without one or more specific features or advantages of a particular example. In other cases, additional features and advantages may be recognized in certain examples that may not be present in all examples. Furthermore, although various examples of the wire harness assembly system 100 and methods 1400, 1500, 3000 for assembling electrical conduit modules have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

Claims

1. A wire harness assembly system (100) for assembling an electrical conduit module, the wire harness assembly system comprising: a pipe assembly fixture (202) disposed on a top surface (204) of a workpiece support structure (206); a harness shuttle subsystem (208) comprising a first shuttle (210) disposed on an upper surface (212) of a tool support structure (214) and a second shuttle (216) disposed on the upper surface (212); at least one robotic manipulator (218) disposed on the upper surface (212) of the tool support structure (214); as well as A system controller (220) in operative communication with the harness shuttle subsystem (208) and the at least one robotic manipulator (218) to control placement of a harness (300) from the first shuttle (210) and the second shuttle (216) to the pipe assembly fixture (202).

2. The wire harness assembly system according to claim 1, wherein: The electrical conduit module is configured to be installed in an end product as a modular component of an electrical conduit architecture for the end product.

3. The wire harness assembly system according to claim 2, wherein: The end product includes at least one of an aircraft, a rotorcraft, a bus, a passenger transport vehicle, a military transport vehicle, a combat military vehicle, a power plant, a drone, a boat, a ferry, a cruise ship, a naval vessel, a commercial building, and a residential building.

4. The wire harness assembly system according to claim 1, wherein: The electrical conduit module is at least one of: about 4 inches wide to about 36 inches wide; about 8 inches wide to about 24 inches wide; and about 14 inches wide to about 18 inches wide.

5. The wire harness assembly system according to claim 1, wherein: The electrical conduit module is at least one of: about 2 feet long to about 100 feet long; about 10 feet long to about 80 feet long; about 20 feet long to about 60 feet long; about 30 feet long to about 50 feet long; and about 40 feet long.

6. The wire harness assembly system according to claim 1, wherein: The workpiece support structure (206) includes a transfer table.

7. The wire harness assembly system according to claim 6, wherein: The transfer station includes at least one of a moving cart, a work table having rollers on a top side, and a support structure having a conveyor belt.

8. The wire harness assembly system according to claim 1, wherein: The at least one robotic manipulator (218) includes one or more of at least one robotic arm, at least one 4-axis robotic arm, at least one 6-axis robotic arm, at least one 7-axis robotic arm, at least one selectively compliant joint robotic arm, at least one collaborative robot, at least one electromechanical manipulator, at least one automatic mechanical manipulator, at least one semi-automatic mechanical manipulator, at least one fixed actuator assisted manipulation robot, and at least one semi-manual use robot.

9. A method (1400) for assembling an electrical conduit module, the method comprising: receiving (1402) a pipe assembly fixture (202) from a pipe preparation area (106) on a workpiece support structure (206) adjacent to a tool support structure (214); receiving (1404) a wire harness (300) from a wire harness preparation system (102) for placement in the conduit assembly fixture (202), the wire harness (300) including a first termination end (306) and a second termination end (308); Positioning (1406) the harness (300) on the upper surface (212) of the tool support structure (214) between a first shuttle (210) holding the first termination end (306) and a second shuttle (216) holding the second termination end (308); picking up (1408) the wire harness (300) having the first termination end (306) and the second termination end (308) from the upper surface (212) of the tool support structure (214), the first shuttle (210), and the second shuttle (216); and The wiring harness (300) is placed (1410) at a predetermined position in the pipe assembly fixture (202).

10. A method (3000) for assembling an electrical conduit module, the method comprising: receiving (3002) a pipe assembly fixture (202) from a pipe preparation area (106) on a workpiece support structure (206) adjacent to a tool support structure (214); receiving (3004) a wire harness (300) from a wire harness preparation system (102) for placement in the conduit assembly fixture (202), the wire harness (300) including a first termination end (306) and a second termination end (308); Positioning (1406) the harness (300) on the upper surface (212) of the tool support structure (214) between a first shuttle (210) holding the first termination end (306) and a second shuttle (216) holding the second termination end (308); picking up (3008) the wire harness (300) having the first termination end (306) and the second termination end (308) from the upper surface (212) of the tool support structure (214), the first shuttle (210), and the second shuttle (216); placing (3010) the wiring harness (300) at a predetermined position in the pipe assembly fixture (202); Repeating (3012) the receiving (3002, 3004), positioning (3006), picking (3008), and placing (3010) of the harness (300) for the next harness (300) until all harnesses designated for autonomous placement in the conduit assembly fixture (202) are placed; and The conduit assembly fixture (202) is transferred (3014) to a rear harness assembly area (108) for performing a manual assembly process on the conduit assembly fixture (202) to prepare the electrical conduit module for installation in a final product.

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