Wire assembly systems and methods for assembling electrical raceway modules

Abstract

To provide a wire assembly system and method for assembling an electrical raceway module.SOLUTION: A wire assembly system 100 comprises: a raceway assembly fixture 202 disposed on a top surface 204 of a workpiece support structure 206; a wire 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; at least one robotic manipulator 218 disposed on the upper surface of the tool support structure; and a system controller 220 in operative communication with the wire shuttle subsystem and the at least one robotic manipulator to control placement of a wire from the first shuttle and the second shuttle to the raceway assembly fixture.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present disclosure relates generally to wire assembly systems for assembling electric raceway modules, and more particularly to techniques for assembling electric raceway modules. Various techniques are used to control one or more robotic manipulators and wire shuttle subsystems to assemble electric raceway modules in a raceway assembly tool. [Background technology]

[0002] Commercial practices for manufacturing wire harnesses have remained virtually unchanged since the 1960s. For raceway wiring, individual wires are prepared, terminated to a first-end connector, bundled into individual harnesses, terminated to a second-end connector, and placed in a bundle on a raceway support. The raceway support is then transported to a factory and installed on the final product, such as an aircraft. This process can currently take 45 man-days. Additionally, the current process includes many non-value-added steps associated with packaging, shipping, receiving, and unpacking. This process can result in large work-in-process buffers due to resource shortages and long lead items.

[0003] An electrical wiring raceway comprises a number of electrical wires routed along the length of an end product to distribute data, signals, and power throughout the end product. For example, an aircraft typically contains four or five raceways routed along its length. The raceways are physically separated from one another to mitigate physical threats such as engine blade outs or bomb blasts.

[0004] Raceways are traditionally assembled using the following process: Long wire bundles are assembled, tested, wound, packaged, and shipped to an electrical system responsibility center. These wire bundles may be assembled by a third party. The electrical system responsibility center receives the wire bundles, unwinds them, and assembles them with other similar bundles on a long assembly table. The wire bundles are tied and / or secured together and attached to spanner bar substructures. These long assemblies are then wound and placed on a transfer tool for transport to the final product assembly plant. At the final product assembly plant, the assembly is unwound, carried into the final product, lifted, and installed. For final products such as aircraft, oversized transfer tools may be used to avoid winding, unwinding, and lifting operations. Traditional raceway assembly is based on the final product production line.

[0005] Existing raceways, wiring harnesses, and wire bundles can contain wires ranging from 24 inches to 100 feet. Current techniques for assembling such wires in raceways require a significant amount of manual labor. For example, there are no known solutions for autonomously managing various wire lengths.

[0006] Accordingly, those skilled in the art continue to conduct research and development efforts aimed at improving techniques for autonomously preparing wire and autonomously transporting wire that has been prepared autonomously and / or manually. Summary of the Invention

[0007] The following discloses exemplary embodiments of a wire assembly system and a method for assembling an electrical raceway module. The following lists exemplary embodiments of the subject matter of the present disclosure, but this list is not exhaustive and may include what is or is not claimed.

[0008] In one example, a wire assembly system for assembling an electric raceway module includes a raceway assembly tool, a wire shuttle subsystem, at least one robotic manipulator, and a system controller. The raceway assembly tool is disposed on a top surface of a work support structure. The wire 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 functional communication with the wire shuttle subsystem and the at least one robotic manipulator and controls the placement of wires from the first shuttle and the second shuttle into the raceway assembly tool.

[0009] In one example, a method for assembling an electrical raceway module includes: (1) receiving a raceway assembly tool from a raceway preparation area at a work support structure, wherein the work support structure is positioned alongside a tool support structure; (2) receiving a wire for placement in the raceway assembly tool from a wire preparation system, wherein the wire includes a first end portion and a second end portion; (3) positioning the wire on an upper surface of the tool support structure between a first shuttle holding the first end portion and a second shuttle holding the second end portion; (4) picking up the wire having the first end portion and the second end portion from the upper surface of the tool support structure, the first shuttle, and the second shuttle; and (5) placing the wire in a predetermined position in the raceway assembly tool.

[0010] In another example, a method for assembling an electrical raceway module includes: (1) receiving a raceway assembly tool at a work support structure from a raceway preparation area, wherein the work support structure is positioned alongside a tool support structure; (2) receiving a wire from a wire preparation system for placement in the raceway assembly tool, wherein the wire includes a first end portion and a second end portion; (3) positioning the wire on an upper surface of the tool support structure between a first shuttle holding the first end portion and a second shuttle holding the second end portion; and (4) attaching the wire to the first end portion and the second end portion. (5) picking up the wire having an end from the top surface of the tool support structure, the first shuttle, and the second shuttle; (6) placing the wire in a predetermined position in the raceway assembly tool; (7) repeating the receiving, positioning, picking up, and placing of the wire for the next wire until all wires designated for autonomous placement in the raceway assembly tool have been placed; and (8) transporting the raceway assembly tool to a post-wire assembly area in preparation for attachment of the electrical raceway module to a final product and performing manual assembly operations in the raceway assembly tool.

[0011] Other examples of the disclosed wire assembly system and method for assembling an electrical raceway module will become apparent from the following detailed description, the accompanying drawings, and the appended claims. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 is a functional block diagram illustrating an example manufacturing system for assembling wires, a raceway assembly tool, and an electrical raceway module. [Figure 2] FIG. 1 is a functional block diagram illustrating an example of a wire assembly system for assembling an electrical raceway module. [Figure 3] FIG. 2 is a front view showing an example of a wire. [Figure 4]4 is a front perspective view showing an example of a wire carrier for carrying the wire shown in FIG. 3. FIG. [Figure 5] 3 is a top functional diagram showing an example of a raceway assembly tool in the wire assembly system of FIG. 2. [Figure 6] FIG. 10 is a top functional view illustrating another example of a wire assembly system for assembling an electrical raceway module. [Figure 7] FIG. 7 is a functional block diagram showing an example of a wire shuttle subsystem in the wire assembly system of FIG. 6. [Figure 8A] FIG. 7 is a top functional diagram showing a portion of the wire assembly system of FIG. 6. [Figure 8B] FIG. 7 is a top functional view showing another portion of the wire assembly system of FIG. 6. [Figure 9] 7 is a perspective view showing an example of a portion of a wire shuttle subsystem in the wire assembly system of FIG. 6. [Figure 10] FIG. 7 is a perspective view showing an example of an insertion robot manipulator in the wire assembly system of FIG. 6. [Figure 11] FIG. 7 is a perspective view showing an example of a transfer robot manipulator in the wire assembly system of FIG. 6. [Figure 12] FIG. 7 is a perspective view showing an example of a working robot manipulator in the wire assembly system of FIG. 6. [Figure 13] FIG. 7 is a perspective view showing another example of an insertion robot manipulator in the wire assembly system of FIG. 6. [Figure 14] FIG. 1 is a flow diagram illustrating an example method for assembling an electrical raceway module. [Figure 15] 15 is a flow diagram illustrating another example of a method for assembling an electrical raceway module in combination with FIG. 14. [Figure 16] FIG. 15 is a flow diagram illustrating an example of receiving raceway assembly tooling in the method of FIG. 14. [Figure 17] FIG. 15 is a flow diagram illustrating another example of receiving a raceway assembly tool in the method of FIG. 14. [Figure 18]15 is a flow diagram illustrating an example of receiving a wire in the method of FIG. 14. [Figure 19] FIG. 19 is a flow diagram illustrating an example of picking up the coil of wire shown in FIG. [Figure 20] 19 is a flow diagram illustrating an example of the placement of the coil, first terminal end, and second terminal end of FIG. 18. FIG. [Figure 21] FIG. 13 is a front perspective view showing an example of an end effector for the working robot manipulator of FIG. 12. [Figure 22] 15 is a flow diagram showing an example of wire positioning in the method of FIG. 14. [Figure 23] FIG. 23 is a flow diagram showing an example of the movement of the first shuttle in FIG. 22. [Figure 24] 23 is a flow diagram showing an example of the movement of the second shuttle of FIG. 22. FIG. [Figure 25] FIG. 15 is a flow diagram illustrating an example of picking up a wire in the method of FIG. [Figure 26] FIG. 15 is a flow diagram showing an example of wire placement in the method of FIG. 14. [Figure 27] 15 is a flow diagram illustrating another example of wire pick-up and placement in the method of FIG. 14. [Figure 28] 27 is a flow diagram illustrating yet another example of wire pick-up and placement in the method of FIG. 14. FIG. [Figure 29] 27 and 28 are flow diagrams illustrating yet another example of wire pick-up and placement in the method of FIG. 14. [Figure 30] FIG. 10 is a flow diagram illustrating another example of a method for assembling an electrical raceway module. [Figure 31] FIG. 31 is a flow diagram illustrating an example of receiving raceway assembly tooling in the method of FIG. 30. [Figure 32] 31 is a flow diagram illustrating an example of receiving a wire in the method of FIG. 30. [Figure 33] FIG. 31 is a flow diagram showing an example of wire positioning in the method of FIG. 30. [Figure 34] FIG. 31 is a flow diagram illustrating an example of picking up a wire in the method of FIG. 30. [Figure 35] FIG. 31 is a flow diagram showing an example of wire placement in the method of FIG. 30. [Figure 36] FIG. 31 is a flow diagram illustrating another example of wire pick-up and placement in the method of FIG. 30. [Figure 37] FIG. 1 is a block diagram illustrating an aircraft manufacturing and service methodology implementing one or more example methods for assembling electric raceway modules of the present disclosure. [Figure 38] 1 is a schematic diagram of an aircraft incorporating a raceway architecture assembled using one or more examples of the wire assembly system and method for assembling electrical raceway modules of the present disclosure. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0013] Various examples of the disclosed wire assembly system 100 and methods 1400, 1500, 3000 for assembling electrical raceway modules provide a technique for autonomously manufacturing raceways by using a robotic manipulator 218 to route individual wires 300 through a raceway assembly tool 202 and insert first and second terminations 306, 308 into electrical connectors 512. The raceway assembly tool 202 is transported from the raceway preparation area 106 to the wire assembly system 100, ready to begin automated routing of the wires 300 from the wire preparation system 102 (see, e.g., FIGS. 1-3 ). For example, unshielded solid wire, shielded cable, and unarmored cable are prepared in the wire preparation system 102 and loaded onto overhead carriers within the wire transport system 104 for transport to the wire assembly system 100. In the post-wire assembly area 108, manual cable installation, dressing of the wires 300, and quality inspection occur. For example, Quadrax, fiber optic, and coaxial cables are prepared in wire preparation system 102 and then manually routed in post-wire fabrication area 108, which results in completed electrical raceway modules ready for installation in the final product (e.g., an aircraft).

[0014] A spanner bar supply line to the raceway preparation area 106 creates a spanner bar kit for assembling each raceway module. This kit includes a spanner bar with the necessary flyaway wiring components and temporary (i.e., non-flyaway) wiring components attached to it for assembling the raceway module. A connector supply line to the raceway preparation area 106 creates a connector kit for assembling each raceway module. This kit includes connectors 512 and associated components for assembling the raceway module. This kit also includes both modular and standard connectors as needed.

[0015] The wire preparation system 102 processes individual, terminated cables to final length and loads them onto overhead carriers in a primarily autonomous manufacturing process. The autonomous manufacturing methods are specialized for each type of wire 300. Unshielded solid conductors are prepared by cut-through crimping. Shielded and unjacketed cables are prepared by cut-through modular insert or crimp installation. The wire preparation system 102 also processes individual, terminated cables to final length and loads them onto overhead carriers using dedicated moving lines. Quadrax, coaxial, fiber optic, and specialty cables are prepared by cut-through crimping of modular inserts. The wire transport system 104 includes an overhead transport system that transports the wire 300 from the wire preparation system 102 to the wire assembly system 100. The wire transport system 104 can also transport the wire 300 to a post-wire assembly area 108. The wire transport system 104 is a transport, sorting, and buffering system with redundant paths to accommodate unplanned downtime in upstream and downstream work cells. The raceway preparation area 106 is where the raceway assembly tooling 202 is assembled. In preparation for the wire assembly system 100, flyaway and temporary (i.e., non-flyaway) hardware is installed.

[0016] The wire assembly system 100 includes a work robot manipulator 614 and a wire shuttle subsystem 208 to retrieve the wire 300 from the wire transport system 104 and position the wire along the raceway assembly fixture 202. The wire assembly system 100 provides robotic pick-and-place operations for the wire 300 into the raceway assembly fixture 202 and robotic insertion of the first and second ends 306, 308 of the wire 300. For unshielded solid wires, crimped ends are inserted into connectors 512, 518 (e.g., modular or standard). For shielded, unarmored cables, modular connector inserts are attached to the retainer.

[0017] The post-wire assembly area 108 is where temporary (i.e., non-flyaway) hardware is removed from the raceway assembly fixture 202. The post-wire assembly area 108 can also be used for manual routing and installation of cables, such as quadrax, fiber optic, coaxial, and specialty cables. Cable dressing, bundling, securing, and storage can also occur in the post-wire assembly area 108. Additionally, final assembly and closing of connectors 512 can also occur in the post-wire assembly area 108. The post-wire assembly area 108 is used for various final assembly operations and testing, including continuity testing and quality inspection.

[0018] The raceway assembly tool 202 (see FIG. 5) includes one or more longitudinal wiring lanes 516 along which groups of wires 300 are routed. A longitudinal wiring lane 516 typically accommodates wires 300 with only one separation code. The raceway assembly tool 202 includes non-flyaway wire routing supports 514 for each longitudinal wiring lane 516, positioned alongside the frame or structural element of the end product on which the electrical raceway modules are mounted. These non-flyaway wire routing supports 514 support the wires 300 as they are laid along a given longitudinal wiring lane 516 during both automated and manual wiring processes.

[0019] The raceway assembly fixture 202 may further include non-flyaway wire routing supports 522 for supporting wires 300 branching from the vertical wiring lanes 516 to the vertical side plates 504 of the raceway assembly fixture 202. These wire routing supports 522 support wires that bend from the vertical wiring lanes 516 and extend to brackets of connectors 518 or printed wiring boards 520 mounted on the vertical side plates 504 during the assembly process of the electrical raceway module, thereby forming a wiring breakout. Note that the wires 300 may not be routed between the opposing long sides of the raceway assembly fixture 202 within a single frame bay. If a vertical wiring lane 516 does not have a branch portion within a given frame bay, that vertical wiring lane 516 does not include wire routing supports 522 for the branch portion. For example, other wire routing supports 514 may be added to the raceway assembly tool 202 that can be manually used in the post-wire assembly area to further tidy and group the wires at the branch points. The wire assembly system 100 may route the wires over these wire routing supports 514.

[0020] In one example, the wire fabrication system 100 includes a raceway transport table, a wire work station, a shuttle system, a selectively compliant articulated robotic arm, a seven-axis robot, a control station, a safety cell enclosure, a LIDAR foot detector, a light fence, and a maintenance cell. The raceway assembly tool 202 is fed from a raceway preparation area and manually loaded onto one end of a raceway conveyor that supports the entire length of the raceway assembly tool 202. The raceway conveyor retrieves the raceway assembly tool 202 and positions it within the wire fabrication system 100. The wire work station, shuttle system, selectively compliant articulated robotic arm, and seven-axis robot are positioned along the raceway assembly tool 202 to remove individual wires 300 from carriers in the wire transport system 104 and feed the wires 300 to the shuttle system. Empty carriers continue through the wire transport system and are refilled at the wire preparation system 102. The shuttle system is an automated system positioned along the raceway assembly tool 202. The shuttle system includes two shuttles, each of which holds one end of a wire 300 and can move along rails to extend the wire and position it along the raceway assembly tool 202 .

[0021] Selectively compliant articulated robotic arms are positioned, for example, every 24 inches along the raceway assembly fixture 202. These robotic arms pick up wires 300 from the shuttle system rails and place the wires 300 onto branch wire routing supports 514 positioned vertically in the raceway assembly fixture 202.

[0022] The seven-axis robot includes two six-axis robots, each mounted on a rail (i.e., the seventh axis) along the raceway assembly tool 202 between the shuttle system and the selectively compliant articulated robot arm. The seven-axis robots include end effectors capable of picking up wires 300 from the shuttles of the shuttle system and inserting the wire ends into connectors 512, 518, respectively, mounted on the raceway assembly tool 202. For example, electrical contacts of solid, unshielded wires are inserted by the robots into the cavities of the connectors 512, 518. This process uses a vision system and force / torque feedback techniques. Similarly, modular connector inserts for cables are inserted by the robots into openings in modular connector receptacles mounted on the raceway assembly tool 202. This process also uses a vision system and force / torque feedback techniques.

[0023] Control stations provide human-machine interfaces for personnel. These human-machine interfaces are located at both ends of the raceway assembly tool 202. A safety cell enclosure encloses most of the raceway transport table, work stations, shuttle system, selectively compliant articulated robot arm, and 7-axis robot (including its rails). The safety cell may span multiple adjacent wire assembly systems 100. Portions of the raceway transport table may be located outside the walls of the safety cell to facilitate loading and unloading of the raceway assembly tool 202 from the raceway preparation area. Tunnels and light gates can be used to separate personnel from operations within the safety enclosure and to allow loading and unloading of the raceway assembly tool 202 even while an adjacent wire assembly system 100 is operating within the safety enclosure. The wire transport system 104 delivers wire 300 to work stations located within the safety enclosure and delivers empty transport carriers out of the safety enclosure.

[0024] LIDAR foot detectors monitor the area immediately above the safety enclosure floor to detect worker entry. These detectors detect a worker at the wire assembly system 100 and cause the wire assembly system 100 and adjacent wire assembly systems 100 to operate in slow-speed mode while the worker holds the safety button on the control pendant in the neutral position (i.e., not fully depressed, but not fully released). Optical fences separate the wire assembly systems 100 from each other. When the optical fences are activated, both adjacent wire assembly systems 100 operate in slow-speed mode while the worker holds the safety button on the control pendant in the neutral position (i.e., not fully depressed, but not fully released). This mode remains until the LIDAR foot detectors no longer detect a worker and the worker resumes work at each production line control station. Maintenance cells are areas used for equipment repair, maintenance, and spare parts storage.

[0025] 13-36 illustrate various examples of methods 1400, 1500, and 3000 for assembling an electrical raceway module. The methods 1400, 1500, and 3000 for assembling an electrical raceway module include receiving a wire 300 and routing the wire 300 in a raceway assembly tool 202. A worker at the input end of the wire assembly system 100 may load the raceway assembly tool 202 onto a transport table from outside the safety fence. The wire assembly system 100 then loads the raceway into the safety fence through a tunnel, which also includes a light gate to prevent workers or their limbs from entering. Once the entire raceway assembly tool 202 is delivered to the transport table, the transport table positions and secures the tool in place. A worker initiates production via a human-machine interface. Individual wires 300 arrive on carriers from the wire transport system 104. The worker robot removes the wound wire 300 from the carrier and places it in the uncoiler, placing each end of the wire 300 into a first end holder and a second end holder, respectively. The end holders hold electrical contacts or modular connector inserts located on each end of the wire in repeatably controllable positions and orientations. The second end holder is located in the rotating portion of the uncoiler pan. The wire transport system 104 then moves the empty carrier out so that the next carrier with the next wire 300 can be introduced.

[0026] Next, the first end of the wire 300 is transferred by the work robot to the first shuttle of the wire shuttle system. The first shuttle unwinds the wire along a shuttle rail at a speed of, for example, about 6 feet per second. The wire 300 rotates in the uncoiler, thereby feeding the wire 300. The second end of the wire 300 rotates with the uncoiler plate. The first shuttle slows down to a speed of, for example, about 1 foot per second during the last foot of unwinding the wire from the uncoiler. When the unwinding of the wire 300 is detected by the camera, the work robot transfers the second end from the uncoiler to the second shuttle. The work robot may then pick up the next wire 300 from the wire transport system 104 and place the wire 300 in the uncoiler.

[0027] The shuttle system moves, for example, at a speed of about 6 feet per second to position the wire at a target center point along the raceway assembly tool 202. The first shuttle may position the first end of the wire 300 approximately 99% of the halfway distance beyond the target center point of the wire 300. The second shuttle may position the second end of the wire 300 approximately 99% of the halfway distance to the target center point of the wire 300. The shuttles slowly move away from each other until, for example, about 3 pounds of tension is detected by at least one of the first and second shuttles. Then, both shuttles stop and retract, for example, about 0.4% of the length of the wire 300. At this point, the wire 300 is approximately centered at the target location, extended and untensioned, with length tolerances evenly distributed at the first and second ends of the wire. Note that both shuttles each include a force sensor, and both shuttles stop when either of these force sensors detects a predetermined force threshold (e.g., 3 pounds of tension).

[0028] The two seven-axis robots and a selectively compliant articulated robot arm located between the two seven-axis robots move to pick up the wire from the shuttle system. The two seven-axis robots pick up the contacts / inserts on the first and second ends of the wire 300. Once the wire 300 is removed from the shuttle system, the shuttle returns to its home position to receive the next wire 300. The two seven-axis robots and the active selectively compliant articulated robot arm move the wire 300 directly above the vertical wire routing supports 514 in the raceway assembly fixture 202. With the two seven-axis robots holding the wire ends, the selectively compliant articulated robot arm places the wire on the vertical wire routing supports 514 and, for wires 300 branching off from the vertical routing lane 516, also on the corresponding wire routing supports 522. The selectively compliant articulated robot arm then begins to retract to its home position.

[0029] The two seven-axis robots move along a spherical, elevated path centered on the last vertical wire routing support 514 or branch support 522, positioning the wire end directly above the target electrical connector 512. This elevated path prevents slack in the wire 300 from getting tangled in the foam board element. The two seven-axis robots move to the reference point of the target electrical connector 512, 518. Using an insertion subroutine, the two seven-axis robots insert the end of the wire 300 into the connector 512, 518 and perform a retention test. The two seven-axis robots then retreat and adjust their position for the next wire 300, as needed. This process is repeated until the remaining wires 300 have been placed in the raceway assembly fixture 202. A worker at the output end of the wire assembly system 100 removes the raceway for transport to the post-wire assembly area 108. This is accomplished, for example, by pressing and holding a remove button on the human machine interface to control the transport table to bring the raceway assembly tool from the wire assembly system into the post-wire assembly area 108 .

[0030] Referring generally to Figures 1-7, the present disclosure relates to a wire assembly system 100 for assembling, for example, an electrical raceway module. Figure 1 illustrates an example of a manufacturing system, a raceway assembly tool 202, and an electrical raceway module for assembling a wire 300. Figure 2 illustrates an example of a wire assembly system 100 for assembling an electrical raceway module. Figure 3 illustrates an example of a wire 300. Figure 4 illustrates an example of a wire carrier 400 for transporting the wire 300 of Figure 3. Figure 5 illustrates an example of a raceway assembly tool 202 in the wire assembly system 100 of Figure 2. Figure 6 illustrates another example of a wire assembly system 100 for assembling an electrical raceway module. Figure 7 illustrates an example of a wire shuttle subsystem 208 in the wire assembly system 100 of Figure 6.

[0031] 1-7 , in one or more examples, a wire assembly system 100 for assembling an electrical raceway module includes a raceway assembly tool 202, a wire shuttle subsystem 208, at least one robotic manipulator 218, and a system controller 220. The raceway assembly tool 202 is disposed on a top surface 204 of a work support structure 206. The wire shuttle subsystem 208 includes a first shuttle 210 disposed on a top surface 212 of a tool support structure 214, and a second shuttle 216 disposed on the top surface 212. The at least one robotic manipulator 218 is disposed on the top surface 212 of the tool support structure 214. The system controller 220 is in operative communication with the wire shuttle subsystem 208 and the at least one robotic manipulator 218 and controls the placement of a wire 300 from the first shuttle 210 and the second shuttle 216 into the raceway assembly tool 202.

[0032] In another example of the wire assembly system 100, the electrical raceway modules are configured to be incorporated into an end product as modular components of the electrical raceway architecture for that end product. In yet another example, the end product includes an aircraft, a rotorcraft, a bus, a passenger transport vehicle, a military transport vehicle, an operational military vehicle, a power plant, an unmanned aerial vehicle, a ship, a ferry, a cruise ship, a naval vessel, a commercial building, a residential building, or any other suitable end product, in any suitable combination. In yet another example of the wire assembly system 100, the electrical raceway modules have a width of about 4 inches to about 36 inches, a width of about 8 inches to about 24 inches, a width of about 14 inches to about 18 inches, or other suitable width dimensions. In yet another example of the wire assembly system 100, the electrical raceway modules have a length of about 2 feet to about 100 feet, a length of about 10 feet to about 80 feet, a length of about 20 feet to about 60 feet, a length of about 30 feet to about 50 feet, a length of about 40 feet, or other suitable length dimensions.

[0033] In yet another example of the wire fabrication system 100, the workpiece support structure 206 includes a transport table. In yet another example, the transport table includes a mobile cart, a table with rollers on its top surface, a support structure with a transport belt, or other suitable transport table, in any suitable combination. In another example of the wire fabrication system 100, the at least one robotic manipulator 218 includes at least one robotic arm, at least one four-axis robotic arm, at least one six-axis robotic arm, at least one seven-axis robotic arm, at least one selective compliance articulated robotic arm, at least one collaborative robot, at least one electromechanical manipulator, at least one automated mechanical manipulator, at least one semi-automated mechanical manipulator, at least one fixed-actuator tending robot, at least one semi-manual robot, or other type of robotic manipulator, in any suitable combination.

[0034] In yet another example of the wire assembly system 100, the wire assembly system 100 is configured to receive the wire 300 on a wire carrier 400 from the wire preparation system 102 via the wire transport system 104. In yet another example, the wire carrier 400 includes at least one coil holder 402, a first end clamp 404, a second end clamp 406, and a wire carrier identification element 408. In yet another example, the wire 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 yet another example, the wire 300, as received, includes a coil 302 having a breakout point 304 at which a first end portion 306 of the wire 300 and a second end portion 308 of the wire 300 branch off from the coil 302. Wire 300 also includes a first wire marker 310 located near first end 306 and a second wire marker 312 located near second end 308. In still other examples, wire 300 includes a solid wire, a twisted pair, a multi-conductor cable, a shielded cable, an unarmored cable, a coaxial cable, a matched impedance cable, a fiber optic cable, or any other suitable type of wire or cable in any suitable combination.

[0035] In yet another example of the wire assembly system 100, the raceway assembly tool 202 includes a raceway framework 502, an electrical connector 512, and a wire routing support 514. The raceway framework 502 includes longitudinal side plates 504, transverse end plates 506, longitudinal support members 508 disposed between the transverse end plates 506, and transverse support members 510 disposed between the longitudinal side plates 504. The electrical connector 512 is disposed near the transverse end plates 506. The wire routing support 514 is attached to the transverse support members 510 to form longitudinal wiring lanes 516. In yet 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 yet another example, the raceway assembly tool 202 also includes at least one additional electrical connector 518, at least one printed wiring board 520, and a branch wiring support 522. At least one additional electrical connector 518 is provided adjacent at least one of the vertical side panels 504. At least one printed wiring board 520 is mounted to any suitable combination of one or more of the vertical side panels 504, one or more horizontal end panels 506, one or more vertical support members 508, one or more horizontal support members 510, or other suitable mounting surfaces. Branch wiring supports 522 are attached to the horizontal support members 510 to form horizontal wiring lanes 524 that branch off from the one or more vertical wiring lanes 516.

[0036] In yet another example of the wire assembly system 100, the first shuttle 210 is configured to receive and temporarily hold the first end 306 of the wire 300, and the second shuttle 216 is configured to receive and temporarily hold the second end 308 of the wire 300. The system controller 220 and the wire shuttle subsystem 208 are configured to position the first shuttle 210 and the second shuttle 216 to extend the wire 300 longitudinally on the upper surface 212 of the tool support structure 214. In yet another example, the system controller 220, the wire shuttle subsystem 208, and the at least one robotic manipulator 218 are configured to place the wire 300 having the first end 306 and the second end 308 at a predetermined position in the raceway assembly tool 202.

[0037] In yet another 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 wire 300 from between the first shuttle 210 and the second shuttle 216 and place the wire 300 in a predetermined position on one or more wire routing supports 514 in the raceway assembly tool 202. In yet another 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 suitable robotic manipulator in any suitable combination. In yet another example, the at least one transfer robotic manipulator 602 includes multiple transfer robotic manipulators 602 spaced apart vertically along the upper surface 212 of the tool support structure 214. In still other examples, the multiple transfer robot manipulators 602 are spaced apart at any suitable combination of about 1 foot to about 2 feet, about 2 feet to about 3 feet, about 3 feet to about 4 feet, or other suitable spacings.

[0038] 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 configured to pick up the first end portion 306 of the wire 300 from the first shuttle 210 and insert the first end portion 306 into the predetermined source electrical connector 512, 518 at the first predetermined location of the raceway assembly tool 202. In yet another example, the at least one insertion robotic manipulator 604 includes at least one robotic arm, at least one six-axis robotic arm, at least one seven-axis robotic arm, at least one collaborative robot, or other suitable robotic manipulator in any suitable combination. In yet another example, at least one insertion robot manipulator 604 is configured to pick up the second end portion 308 of the wire 300 from the second shuttle 216 and insert the second end portion 308 into a predetermined terminal electrical connector 512, 518 at a second predetermined position of the raceway assembly tool 202.

[0039] 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 attached to a first robotic transport unit 608 disposed on the upper surface 212 of the tool support structure 214, the first robotic transport unit being configured to translate the first insertion robotic manipulator 606 along the length of the raceway assembly tool 202. The first insertion robotic manipulator 606, in conjunction with the first robotic transport unit 608, is configured to pick up the first terminal end 306 of the wire 300 from the first shuttle 210 and insert the first terminal end 306 into the predetermined origin electrical connectors 512, 518 at a first predetermined location on the raceway assembly tool 202. The second insertion robot manipulator 610 is mounted to a second robot transport unit 612 disposed on the upper surface 212 adjacent to the first robot transport unit 608, and the second robot transport unit is configured to translate the second insertion robot manipulator 610 along the length of the raceway assembly tool 202. The second insertion robot manipulator 610, in conjunction with the second robot transport unit 612, is configured to pick up the second termination portion 308 of the wire 300 from the second shuttle 216 and insert the second termination portion 308 into the predetermined end electrical connectors 512, 518 at a second predetermined location on the raceway assembly tool 202.

[0040] In yet another example of the wire assembly system 100, the wire shuttle subsystem 208 further includes a longitudinal channel 702, a first transport assembly 704, a second transport assembly 708, an unwind assembly 712, an image sensor 714, a wire carrier identification detector 715, and a control assembly 716. The longitudinal channel 702 is disposed on the upper surface 212 of the tool support structure 214 and extends along the raceway assembly fixture 202. The first transport assembly 704 is mechanically connected to the first shuttle 210 and positions the first shuttle 210 along a first longitudinal rail 706 of the longitudinal channel 702. The second transport assembly 708 is mechanically connected to the second shuttle 216 and positions the second shuttle 216 along a second longitudinal rail 710 of the longitudinal channel 702. The unwind 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 300, the first terminal end 306 of the wire 300, and the second terminal end 308 of the wire 300. The image sensor 714 is disposed near the unwind assembly 712 and is configured to selectively capture images of the first terminal end 306 and the second terminal end 308, and images indicative of the condition of the coil 302 at the unwind assembly 712. The wire carrier identification detector 715 is disposed near the wire carrier 400 in the wire transport system 104. The wire carrier 400 is configured to transport the wire 300 from the wire preparation system 102 to the wire 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 is in functional communication with the first transport assembly 704, the second transport assembly 708, the unwind assembly 712, the image sensor 714, the wire carrier identification detector 715, and the system controller 220, and controls the movement of the first end portion 306 from the unwind assembly 712 to the first shuttle 210, the movement of the first shuttle 210 along the first longitudinal rail 706, the unwinding of the coil 302 from the unwind assembly 712, the placement of the second end portion 308 from the unwind assembly 712 to the second shuttle 216, and the movement of the second shuttle 216 along the second longitudinal rail 710.

[0041] In yet another example, first transport 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 other suitable drive devices, in any suitable combination. In yet another example, second transport 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 other suitable drive devices, in any suitable combination. In yet another example, image sensor 714 includes a digital camera, a charge-coupled device, an active pixel device, an optical scanner, a laser scanner, or other suitable image sensor, in any suitable combination. In yet another example, wire 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 other suitable detector, in any suitable combination.

[0042] In yet another example, the unwind assembly 712 includes a rotating plate 718, a first end holder 720, and a second end holder 722. The rotating plate 718 is configured to temporarily hold the coil 302 of the wire 300 and to unwind the wire 300 under tension of the first terminal end 306 in conjunction with movement of the first shuttle 210 along the first longitudinal rail 706 of the wire shuttle subsystem 208. The first end holder 720 is disposed adjacent to the rotating plate 718 and is configured to temporarily hold the first terminal end 306 of the wire 300. The second end holder 722 is attached to the rotating plate 718 and is configured to hold the second terminal end 308 of the wire 300. In yet another example, the first end holder 720 includes the first shuttle 210 when disposed on the first longitudinal rail 706 of the longitudinal groove 702 disposed adjacent to the rotating plate 718. In yet another example, wire assembly system 100 further includes a work robot manipulator 614 mounted on a support platform 616 adjacent a proximal end region 618 of tool support structure 214. Work robot manipulator 614 is configured to pick up coil 302, first end portion 306, and second end portion 308 of wire 300 from wire carriers 400 in wire transport system 104. The work robot manipulator is also configured to place coil 302 on rotating plate 718 of unwind assembly 712, place first end portion 306 on first end holder 720, and place second end portion 308 on second end holder 722.

[0043] In yet another example, the work robot manipulator 614 includes any suitable combination of a robotic arm, a six-axis robotic arm, a collaborative robot, an electromechanical manipulator, an automated mechanical manipulator, a semi-automated mechanical manipulator, a work robot with fixed actuators, a semi-manual robot, or any other suitable type of robotic manipulator. In yet another example, the system controller 220 and the work robot manipulator 614 are configured to pick up the first end portion 306 of the wire 300 from the first end holder 720 and place the first end portion 306 on the first shuttle 210. The system controller 220 and the work robot manipulator 614 are also configured to pick up the second end portion 308 of the wire 300 from the second end holder 722 and place the second end portion 308 on the second shuttle 216 when the system controller 220 detects that the wire 300 has been unwound from the rotating plate 718.

[0044] In an alternative example, the second work robot manipulator or other robotic manipulator can be used to pick up the first end portion 306 of the wire 300 from the first end holder 720 and place the first end portion 306 on the first shuttle 210. In a similar alternative, once the system controller 220 detects that the wire 300 has unwound from the rotating plate 718, the second work robot manipulator or other robotic manipulator can be used to pick up the second end portion 308 of the wire 300 from the second end holder 722 and place the second end portion 308 on the second shuttle 216. These alternatives allow the work robot manipulator 614 to prepare to transfer the next wire 300 from the wire carrier 400 to the unwind assembly 712 while the current wire 300 is being unwound from the rotating plate 718.

[0045] Referring generally to Figures 1-7, 12, and 14-29, for example, the present disclosure relates to methods 1400, 1500 for assembling an electrical raceway module. Figure 1 illustrates an example of a manufacturing system, raceway assembly tool 202, and electrical raceway module for assembling wire 300. Figure 2 illustrates an example of a wire assembly system 100 for assembling an electrical raceway module. Figure 3 illustrates an example of wire 300. Figure 4 illustrates an example of a wire carrier 400 for transporting wire 300 of Figure 3. Figure 5 illustrates an example of a raceway assembly tool 202 in the wire assembly system 100 of Figure 2. Figure 6 illustrates another example of a wire assembly system 100 for assembling an electrical raceway module. Figure 7 illustrates an example of a wire shuttle subsystem 208 in the wire assembly system 100 of Figure 6. Figure 12 illustrates an example of a work robot manipulator 614 in the wire assembly system 100 of Figure 6.

[0046] FIG. 14 illustrates an example of a method 1400 for assembling an electric raceway module. FIG. 15, in combination with FIG. 14, illustrates an example of a method 1500 for assembling an electric raceway module. FIG. 16 illustrates an example of receiving a raceway assembly tool 1402 in the method 1400 shown in FIG. 14. FIG. 17 illustrates another example of receiving a raceway assembly tool 1402 in the method 1400 shown in FIG. 14. FIG. 18 illustrates an example of receiving a wire 300 1404 in the method 1400 shown in FIG. 14. FIG. 19 illustrates an example of picking up a coil 302 of a wire 300 1802 shown in FIG. 18. FIG. 20 illustrates an example of placing a coil 302, a first end 306, and a second end 308 shown in FIG. 18. FIG. 21 illustrates an example of an end effector 2100 for the work robot manipulator 614 shown in FIG. 12. FIG. 22 is a flow diagram illustrating an example of wire positioning in the method 1400 shown in FIG. 14. FIG. 23 illustrates an example of movement 2210 of the first shuttle 210 shown in FIG. 22. FIG. 24 illustrates an example of movement 2212 of the second shuttle 216 shown in FIG. 22. FIG. 25 illustrates an example of picking up 1408 of the wire 300 in the method 1400 shown in FIG. 14. FIG. 26 illustrates an example of placing 1410 of the wire 300 in the method 1400 shown in FIG. 14. FIG. 27 illustrates another example of picking up 1408 and placing 1410 of the wire 300 in the method 1400 shown in FIG. 14. FIG. 28, in combination with FIG. 27, illustrates another example of picking up 1408 and placing 1409 of the wire 300 in the method 1400 shown in FIG. 14. FIG. 29, in combination with FIGS. 27 and 28, illustrates yet another example of picking up 1408 and placing 1410 the wire 300 in the method 1400 shown in FIG.

[0047] 1-7, 12, and 14-29, in one or more examples, a method 1400 (see FIG. 14) for assembling an electrical raceway module includes receiving 1402 a raceway assembly tool 202 from the raceway preparation area 106 at a work support structure 206. The work support structure 206 is positioned alongside a tool support structure 214. At 1404, a wire 300 is received from the wire preparation system 102 for placement in the raceway assembly tool 202. The wire 300 includes a first end portion 306 and a second end portion 308. At 1406, the wire 300 is positioned on an upper surface 212 of the tool support structure 214 between a first shuttle 210 holding the first end portion 306 and a second shuttle 216 holding the second end portion 308. At 1408, the wire 300 having the first end 306 and the second 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 300 is placed in position in the raceway assembly tool 202.

[0048] In another example of method 1400, the electrical raceway module is configured to be incorporated into an end product as a modular component of the end product's electrical raceway architecture. In yet 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 military operational vehicle, a passenger ship, a cargo ship, a naval vessel, a commercial building, a residential building, or any other suitable end product, in any suitable combination. In yet another example of method 1400, the electrical raceway module has a width of about 4 inches to about 36 inches, a width of about 8 inches to about 24 inches, a width of about 14 inches to about 18 inches, or other suitable width dimension. In yet another example of method 1400, the electrical raceway module has a length of about 2 feet to about 100 feet, a length of about 10 feet to about 80 feet, a length of about 20 feet to about 60 feet, a length of about 30 feet to about 50 feet, a length of about 40 feet, or other suitable length dimension.

[0049] In yet another example of method 1400, workpiece support structure 206 includes a transport table. In yet another example, the transport table includes a mobile cart, a table with rollers on its upper surface, a support structure with a transport belt, or any other suitable transport table, in any suitable combination. In another example, method 1400 is implemented in wire assembly system 100 configured to receive wire 300 on wire carrier 400 from wire preparation system 102 via wire transport system 104. In yet another example, wire 300, as received, includes a coil 302 having a bifurcation point 304 where a first end 306 of wire 300 and a second end 308 of wire 300 bifurcate from coil 302. Wire 300 also includes a first wire marker 310 disposed near first end 306 and a second wire marker 312 disposed near second end 308. In still other examples, wire 300 includes solid wire, twisted pair, multi-conductor cable, shielded cable, unarmored cable, coaxial cable, matched impedance cable, fiber optic cable, or other suitable types of wire or cable in any suitable combination.

[0050] 1-3, 14, and 15, in one or more examples, a method 1500 (see FIG. 15) for assembling an electrical raceway module includes the method 1400 shown in FIG. 14 and continues from 1410 to 1502, in which steps 1402, 1404, positioning 1406, picking up 1408, and placing 1410 of a wire 300 are repeated for the next wire 300 until all wires designated for autonomous placement in the raceway assembly tool 202 have been placed. In other examples, the method 1500 further includes transporting the raceway assembly tool 202 to a post-wire assembly area 108 and performing manual assembly operations 1504 on the raceway assembly tool 202 in preparation for attachment of the electrical raceway module to a final product.

[0051] 1-7, 12 and 14-29, in another example of a method 1400, receiving 1402 the raceway assembly tool 202 includes receiving 1602 (see FIG. 16) the raceway assembly tool 202 from the raceway preparation area 106 via the raceway transport system. In 1604, the raceway assembly tool 202 is transferred from the raceway transport system to the top surface 204 of the work support structure 206. In 1606, the work support structure 206 with the raceway assembly tool 202 is moved alongside the tool support structure 214. In 1608, the work support structure 206 is secured in place. In yet another example of a method 1400, receiving 1402 the raceway assembly tool 202 includes transferring 1702 (see FIG. 17) the raceway assembly tool 202 from the raceway preparation area 106 onto the work support structure 206. At 1704, the work support structure 206 with the raceway assembly fixture 202 is moved alongside the tool support structure 214. At 1706, the work support structure 206 is locked into place.

[0052] In yet another example of the method 1400, receiving 1404 the wire 300 includes picking up 1802 (see FIG. 18 ) a coil 302 of wire 300 having a first end 306 and a second end 308 from a wire carrier 400 in the wire transport system 104 using a work robot manipulator 614 mounted on a support platform 616 adjacent a proximal end region 618 of the tool support structure 214. At 1804, the coil 302, the first end 306, and the second end 308 are placed, using the work robot manipulator 614, on an unwind assembly 712 located on the upper surface 212 at the proximal end region 618 of the tool support structure 214. In yet another example, picking up 1802 the coil 302 includes picking up 1902 (see FIG. 19 ) the coil 302 of wire 300 from at least one coil holder 402 of the wire carrier 400 using at least one first holding device 2102 of an end effector 2100 attached to the work robot manipulator 614. At 1904, the first terminal end 306 of the wire 300 is picked up from the first end clamp 404 of the wire carrier 400 using a second holding device 2104 of the end effector 2100. At 1906, the second terminal end 308 of the wire 300 is picked up from the second end clamp 406 of the wire carrier 400 using a third holding device 2106 of the end effector 2100.

[0053] In yet another example, placing 1804 the coil 302 includes placing 2002 (see FIG. 20 ) the coil 302 of wire 300 from at least one first holding device 2102 of an end effector 2100 attached to the work robot manipulator 614 onto a rotating plate 718 of an unwind assembly 712. In 2004, a first terminal end 306 of the wire 300 is placed from a second holding device 2104 of the end effector 2100 into a first end holder 720 of the unwind assembly 712. In 2006, a second terminal end 308 of the wire 300 is placed from a third holding device 2106 of the end effector 2100 into a second end holder 722 of the unwind assembly 712. In yet another example, the first end holder 720 includes the first shuttle 210 when positioned near the rotating plate 718.

[0054] In yet another example of the method 1400, a coil 302 of wire 300 having a first end 306 and a second end 308 is placed on an unwind assembly 712 located on the upper surface 212 at the proximal end region 618 of the tool support structure 214. In this example, positioning 1406 of the wire 300 includes obtaining 2202 (see FIG. 22 ) an identification number from a wire carrier identification element 408 on a wire carrier 400 of the wire transport system 104. The identification number uniquely identifies the wire carrier 400 relative to other wire carriers in the wire transport system 104. The identification number corresponds to a unique wire number assigned to the wire 300 in relation to other wires in the electrical raceway module. At 2204, a location within the raceway assembly tool 202 for placing the wire 300, the first end 306 of the wire 300, and the second end 308 of the wire 300 is determined based at least in part on the identification number. At 2206, the first shuttle 210 is moved along the first longitudinal rail 706 to a first pickup position adjacent to the unwind assembly 712. At 2208, the first terminal end 306 of the wire 300 is placed on the first shuttle 210 using a work robot manipulator 614 attached to a support platform 616 adjacent the proximal end region 618 of the tool support structure 214. At 2210, the first shuttle 210 is moved away from the unwind assembly 712 while holding the first terminal end 306, rotating the rotating plate 718 of the unwind assembly 712 until the coil 302 of the wire 300 is unwound. At 2212, the second shuttle 216 is moved along the second longitudinal rail 710 to a second pickup position adjacent to the unwind assembly 712. At 2214 , the second terminal end 308 of the wire 300 is placed from the second end holder 722 of the unwind assembly 712 onto the second shuttle 216 using the work robot manipulator 614 .At 2216, the first shuttle 210 having the first end 306 and the second shuttle 216 having the second end 308 are moved away from the unwinding assembly 712 until the wire 300 is positioned along the target position of the wire 300 in the raceway assembly tool 202.

[0055] In yet another example, movement 2210 of first shuttle 210 and rotation of rotatable plate 718 includes acquiring 2302 (see FIG. 23 ) a series of visual images of rotatable plate 718 while coil 302 of wire 300 is unwound. At 2304, it is determined, based at least in part on the series of visual images, whether coil 302 of wire 300 has unwound from rotatable plate 718. At 2306, once coil 302 has unwound, movement 2210 of first shuttle 210 and rotation of rotatable plate 718 are stopped.

[0056] In yet another 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 second shuttle 216 includes stopping 2402 (see FIG. 24 ) the movement 2216 of the first shuttle 210 and the second shuttle 216 after the wire 300 is positioned along the target position of the wire 300. At 2404, the first shuttle 210 is slowly moved in a direction away from the target position of the wire 300. At 2406, the second shuttle 216 is slowly moved in a direction away from the target position of the wire 300. At 2408, the movement of the first shuttle 210 and the second shuttle 216 in the opposite directions is stopped when at least one of the first force sensor 724 and the second force sensor 726 detects that the tension in the wire 300 exceeds a predetermined tension threshold. At 2410, the first shuttle 210 and the second shuttle 216 are retracted a predetermined amount, thereby removing tension and centering the first end 306 of the wire 300 and the second end 308 of the wire 300 relative to the target position of the wire 300.

[0057] In still other examples, the predetermined tension threshold includes about 1 lb. to about 5 lb. tension, about 2 lb. to about 4 lb. tension, about 3 lb. tension, or other moderate tension. In still other examples, the predetermined amount of retraction of wire 300 toward the target location includes about 0.1% to about 0.7% of the length of wire 300, about 0.2% to about 0.6% of the length of wire 300, about 0.3% to about 0.5% of the length of wire 300, about 0.4% of the length of wire 300, or other suitable retraction distance.

[0058] In another example of the method 1400, picking up 1408 the wire 300 includes moving 2502 (see FIG. 25 ) a first insertion robot manipulator 606 on a first robot transport unit 608 toward the first shuttle 210. The first insertion robot manipulator 606 is attached to the first robot transport unit 608. The first robot transport unit 608 is disposed on the upper surface 212 of the tool support structure 214. In 2504, the first end 306 of the wire 300 is picked up from the first shuttle 210 using the first insertion robot manipulator 606. In 2506, a second insertion robot manipulator 610 on a second robot transport unit 612 is moved toward the second shuttle 216. The second insertion robot manipulator 610 is attached to the second robot transport unit 612. The second robot transport unit 612 is positioned on the upper surface 212 of the tool support structure 214 adjacent to the first robot transport unit 608. At 2508, the second terminal end 308 of the wire 300 is picked up from the second shuttle 216 using the second insertion robot manipulator 610. At 2510, the portion of the wire 300 between the first terminal end 306 and the second terminal end 308 is picked up using at least one transfer robot manipulator 602 attached to the upper surface 212 of the tool support structure 214 adjacent to the first robot transport unit 608 or the second robot transport unit 612. In yet another example, multiple transfer robot manipulators 602 between the first terminal end 306 of the wire 300 and the second terminal end 308 of the wire 300 are positioned at predetermined distances along the upper surface 212 of the tool support structure 214. In still other examples, the predetermined distance includes about 1 foot to about 3 feet, about 1.5 feet to about 2.5 feet, about 2 feet, or any other suitable distance.

[0059] In yet another example of the method 1400, placing 1410 the wire 300 includes placing 2602 (see FIG. 26 ) a portion of the wire 300 between the first end 306 and the second end 308 on the wire routing supports 514, 522 of a predetermined longitudinal routing lane 516 in the raceway assembly tool 202 using at least one transfer robot manipulator 602 mounted on the upper surface 212 of the tool support structure 214 adjacent to a first robot transport unit 608 associated with a first insertion robot manipulator 606 or a second robot transport unit 612 associated with a second insertion robot manipulator 610. The first insertion robot manipulator 606 is mounted on the first robot transport unit 608. The first robot transport unit 608 is disposed on the upper surface 212 of the tool support structure 214. The second insertion robot manipulator 610 is mounted on the second robot transport unit 612. The second robotic transfer unit 612 is positioned on the upper surface 212 of the tool support structure 214. At 2604, the first terminal end 306 of the wire 300 is placed at a predetermined starting electrical connector 512, 518 on the raceway assembly tool 202 using the first insertion robotic manipulator 606. At 2606, the second terminal end 308 of the wire 300 is placed at a predetermined ending electrical connector 512, 518 on the raceway assembly tool 202 using the second insertion robotic manipulator 610. In yet another example, the multiple transfer robotic manipulators 602 between the first terminal end 306 of the wire 300 and the second terminal end 308 of the wire 300 are spaced apart a predetermined distance along the upper surface 212 of the tool support structure 214. In yet another example, the predetermined distance includes about 1 foot to about 3 feet, about 1.5 feet to about 2.5 feet, about 2 feet, or other suitable distances.

[0060] In yet another example of the method 1400, picking up 1408 and placing 1410 the wire 300 includes using a robotic manipulator 218 mounted on the upper surface 212 of the tool support structure 214 to pick up 2702 (see FIG. 27 ) a portion of the wire 300 between the first end 306 and the second end 308. At 2704, the portion of the wire 300 between the first end 306 and the second end 308 is placed on the wire routing supports 514, 522 of a predetermined longitudinal routing lane 516 in the raceway assembly tool 202 using the robotic manipulator 218. In yet another example, picking up 1408 and placing 1410 the wire 300 further includes moving 2802 (see FIG. 28 ) the robotic manipulator 218 on the robotic transport unit 608, 612 towards the first shuttle 210. The robot manipulator 218 is attached to the robot transport units 608, 612. The robot transport units 608, 612 are disposed on the upper surface 212 of the tool support structure 214. At 2804, the first terminal end 306 of the wire 300 is picked up from the first shuttle 210 using the robot manipulator 218. At 2806, the first terminal end 306 of the wire 300 is placed at a predetermined source electrical connector 512, 518 on the raceway assembly tool 202 using the robot manipulator 218. In yet another example, the picking up 1408 and placing 1410 of the wire 300 further include moving 2902 (see FIG. 29 ) the robot manipulator 218 on the robot transport units 608, 612 toward the second shuttle 216. At 2904, the second terminal end 308 of the wire 300 is picked up from the second shuttle 216 using the robotic manipulator 218. At 2906, the second terminal end 308 of the wire 300 is placed into a predetermined terminal electrical connector 512, 518 in the raceway assembly tool 202 using the robotic manipulator 218.

[0061] Referring generally to Figures 1-7 and 30-36, the present disclosure relates to, for example, a method 3000 for assembling an electrical raceway module. Figure 1 illustrates an example of a manufacturing system, raceway assembly tool 202, and electrical raceway module for assembling a wire 300. Figure 2 illustrates an example of a wire assembly system 100 for assembling an electrical raceway module. Figure 3 illustrates an example of a wire 300. Figure 4 illustrates an example of a wire carrier 400 for transporting the wire 300 of Figure 3. Figure 5 illustrates an example of a raceway assembly tool 202 in the wire assembly system 100 of Figure 2. Figure 6 illustrates another example of a wire assembly system 100 for assembling an electrical raceway module. Figure 7 illustrates an example of a wire shuttle subsystem 208 in the wire assembly system 100 of Figure 6.

[0062] FIG. 30 illustrates an example method 3000 for assembling an electrical raceway module. FIG. 31 illustrates an example of receiving 3002 the raceway assembly tool 202 during the method 3000 shown in FIG. 30. FIG. 32 illustrates an example of receiving 3004 the wire 300 during the method 3000 shown in FIG. 30. FIG. 33 illustrates an example of positioning 3006 the wire 300 during the method 3000 shown in FIG. 30. FIG. 34 illustrates an example of picking up 3008 the wire 300 during the method 3000 shown in FIG. 30. FIG. 35 illustrates an example of placing 3010 the wire 300 during the method 3000 shown in FIG. 30. FIG. 36 illustrates another example of picking up 3008 and placing 3010 the wire 300 during the method 3000 shown in FIG. 30.

[0063] 1-7, 12, and 30-36, in one or more examples, a method 3000 (see FIG. 30) for assembling an electrical raceway module includes receiving 3002 a raceway assembly tool 202 from the raceway preparation area 106 at a work support structure 206. The work support structure 206 is positioned alongside the tool support structure 214. At 3004, a wire 300 is received from the wire preparation system 102 for placement in the raceway assembly tool 202. The wire 300 includes a first end portion 306 and a second end portion 308. At 3006, the wire 300 is positioned on the upper surface 212 of the tool support structure 214 between a first shuttle 210 holding the first end portion 306 and a second shuttle 216 holding the second end portion 308. At 3008, a wire 300 having a first end 306 and a second 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 3010, the wire 300 is placed in position in the raceway assembly tool 202. At 3012, the process of receiving 3002, 3004, positioning 3006, picking up 3008, and placing 3010 of the wire 300 is repeated for the next wire 300 until all wires designated for autonomous placement in the raceway assembly tool 202 have been placed. At 3104, the raceway assembly tool 202 is transported to the post-wire assembly area 108 where manual assembly operations are performed in the raceway assembly tool 202 in preparation for attachment of the electrical raceway modules to the final product.

[0064] In another example of the method 3000, receiving 3002 the raceway assembly tool 202 includes receiving 3102 (see FIG. 31 ) the raceway assembly tool 202 from the raceway preparation area 106 via the raceway transport system. In 3104, the raceway assembly tool 202 is transferred from the raceway transport system to the top surface 204 of the work support structure 206. In 3106, the work support structure 206 with the raceway assembly tool 202 is positioned alongside the tool support structure 214. In 3108, the work support structure 206 is secured in place.

[0065] In yet another example of the method 3000, receiving 3004 the wire 300 includes picking up 3202 (see FIG. 32 ) a coil 302 of wire 300 having a first end 306 and a second end 308 from a wire carrier 400 in the wire transport system 104 using a work robot manipulator 614 mounted on a support platform 616 adjacent a proximal end region 618 of the tool support structure 214. In 3204, the coil 302, the first end 306, and the second end 308 are placed, using the work robot manipulator 614, on an unwind assembly 712 located on the upper surface 212 at the proximal end region 618 of the tool support structure 214.

[0066] In yet another example of the method 3000, a coil 302 of wire 300 having a first end 306 and a second end 308 is placed on an unwind assembly 712 located on the upper surface 212 at the proximal end region 618 of the tool support structure 214. In this example, positioning 3006 of the wire 300 includes obtaining 3302 (see FIG. 33 ) an identification number from a wire carrier identification element 408 on a wire carrier 400 of the wire transport system 104. The identification number uniquely identifies the wire carrier 400 relative to other wire carriers in the wire transport system 104. The identification number corresponds to a unique wire number assigned to the wire 300 in relation to other wires in the electrical raceway module. At 3304, a location within the raceway assembly tool 202 for placing the wire 300, the first end 306 of the wire 300, and the second end 308 of the wire 300 is determined based at least in part on the identification number. At 3306, the first shuttle 210 is moved along the first longitudinal rail 706 to a first pickup position adjacent to the unwind assembly 712. At 3308, the first terminal end 306 of the wire 300 is placed on the first shuttle 210 using a work robot manipulator 614 attached to a support platform 616 adjacent the proximal end region 618 of the tool support structure 214. At 3310, the first shuttle 210 is moved away from the unwind assembly 712 while holding the first terminal end 306, and the rotating plate 718 of the unwind assembly 712 rotates until the coil 302 of the wire 300 is unwound. At 3312, the second shuttle 216 is moved along the second longitudinal rail 710 to a second pickup position adjacent to the unwind assembly 712. At 3314 , the second terminal end 308 of the wire 300 is placed from the second end holder 722 of the unwind assembly 712 onto the second shuttle 216 using the work robot manipulator 614 .At 3316, the first shuttle 210 having the first end 306 and the second shuttle 216 having the second end 308 are moved away from the unwinding assembly 712 until the wire 300 is positioned along the target position of the wire 300 in the raceway assembly tool 202.

[0067] In another example of the method 3000, picking up 3008 the wire 300 includes moving 3402 (see FIG. 34 ) a first insertion robot manipulator 606 on a first robot transport unit 608 toward the first shuttle 210. The first insertion robot manipulator 606 is attached to the first robot transport unit 608. The first robot transport unit 608 is disposed on the upper surface 212 of the tool support structure 214. In 3404, the first end 306 of the wire 300 is picked up from the first shuttle 210 using the first insertion robot manipulator 606. In 3406, a second insertion robot manipulator 610 on a second robot transport unit 612 is moved toward the second shuttle 216. The second insertion robot manipulator 610 is attached to the second robot transport unit 612. The second robot transport unit 612 is positioned on the upper surface 212 of the tool support structure 214 adjacent to the first robot transport unit 608. At 3408, the second terminal end 308 of the wire 300 is picked up from the second shuttle 216 using the second insertion robot manipulator 610. At 3410, the portion of the wire 300 between the first terminal end 306 and the second terminal end 308 is picked up using at least one transfer robot manipulator 602 mounted on the upper surface 212 of the tool support structure 214 adjacent to the first robot transport unit 608 or the second robot transport unit 612.

[0068] In yet another example of the method 3000, placing 3010 the wire 300 includes placing 3502 (see FIG. 35 ) a portion of the wire 300 between the first end 306 and the second end 308 on the wire routing supports 514, 522 of a predetermined longitudinal routing lane 516 in the raceway assembly tool 202 using at least one transfer robot manipulator 602 mounted on the upper surface 212 of the tool support structure 214 adjacent to a first robot transport unit 608 associated with a first insertion robot manipulator 606 or a second robot transport unit 612 associated with a second insertion robot manipulator 610. The first insertion robot manipulator 606 is mounted on the first robot transport unit 608. The first robot transport unit 608 is disposed on the upper surface 212 of the tool support structure 214. The second insertion robot manipulator 610 is mounted on the second robot transport unit 612. The second robotic transport unit 612 is positioned on the upper surface 212 of the tool support structure 214. At 3504, the first terminal end 306 of the wire 300 is placed into the predetermined starting electrical connector 512, 518 of the raceway assembly tool 202 using the first insertion robotic manipulator 606. At 3506, the second terminal end 308 of the wire 300 is placed into the predetermined ending electrical connector 512, 518 of the raceway assembly tool 202 using the second insertion robotic manipulator 610.

[0069] In yet another example of the method 3000, picking up 3008 and placing 3010 the wire 300 includes picking up 3602 (see FIG. 36 ) a portion of the wire 300 between the first end 306 and the second end 308 using a robotic manipulator 218 mounted on the upper surface 212 of the tool support structure 214. At 3604, the portion of the wire 300 between the first end 306 and the second end 308 is placed on the wire routing supports 514, 522 of a predetermined longitudinal routing lane 516 within the raceway assembly tool 202 using the robotic manipulator 218. At 3606, the robotic manipulator 218 on the robotic transport unit 608, 612 is moved toward the first shuttle 210. The robotic manipulator 218 is attached to the robotic transport unit 608, 612. The robotic transport units 608, 612 are positioned on the upper surface 212 of the tool support structure 214. At 3608, the first terminal end 306 of the wire 300 is picked up from the first shuttle 210 using the robotic manipulator 218. At 3610, the first terminal end 306 of the wire 300 is placed at a predetermined starting electrical connector 512 of the raceway assembly tool 202 using the robotic manipulator 218. At 3612, the robotic manipulators 218 of the robotic transport units 608, 612 are moved toward the second shuttle 216. At 3614, the second terminal end 308 of the wire 300 is picked up from the second shuttle 216 using the robotic manipulator 218. At 3616, the second terminal end 308 of the wire 300 is placed at a predetermined ending electrical connector 512 of the raceway assembly tool 202 using the robotic manipulator 218.

[0070] The examples of the wire assembly system 100 and methods 1400, 1500, 3000 for assembling electrical raceway modules may be related to or used in the aircraft manufacturing field. Additionally, while the examples are described in an aircraft application, the examples and principles of the present disclosure are applicable to other products in the aerospace industry and other industries, such as the automotive, space, construction, and design and manufacturing industries. Thus, the examples and principles of the present disclosure are applicable to a variety of product applications in the manufacture of various vehicles and the construction of various buildings, in addition to aircraft.

[0071] The above detailed description refers to the accompanying drawings, which illustrate specific examples described in the present disclosure. It should be noted that other examples having different structures or operations do not depart from the scope of the present disclosure. The same reference numerals in different drawings indicate the same features, elements, or components. Throughout this disclosure, any one of multiple elements may be individually referred to as "the element," or multiple elements may be collectively referred to as "the elements," and may be designated by the same reference numeral. Furthermore, in this specification, the term "a" or "an" preceding a feature, element, component, or step does not exclude multiple features, elements, components, or steps, unless otherwise specified.

[0072] Illustrative, non-exhaustive examples of the subject matter disclosed herein have been provided above, and these examples may include those that are or are not recited in the claims. As used herein, the term "example" means that one or more features, structures, elements, components, or characteristics described in connection with that example are included in at least one aspect, embodiment, and / or implementation of the subject matter disclosed herein. Thus, in this disclosure, terms such as "one example," "another example," "one or more examples," and similar terms may, but do not necessarily, refer to the same example. Furthermore, features characterizing one example may, but do not necessarily, include features characterizing other examples. Furthermore, features characterizing one example may, but do not necessarily, be combined with features characterizing other examples.

[0073] As used herein, a system, apparatus, device, structure, article, element, component, or hardware that is "configured" to perform a particular function refers to one that can perform that particular function without any modification, and not one that could perform that particular function with any modification. In other words, a system, apparatus, device, structure, article, element, component, or hardware that is "configured" to perform a particular function refers to one that is specifically selected, made, implemented, utilized, programmed, and / or designed to perform that particular function. As used herein, the term "configured" refers to characteristics that a system, apparatus, structure, article, element, component, or hardware already possesses that enable the system, apparatus, structure, article, element, component, or hardware to perform that particular function without any modification. In this disclosure, a system, apparatus, device, structure, article, element, component, or hardware that is described as "configured" to perform a particular function may also or instead be described as being "adapted" and / or "operable" to perform that function.

[0074] Unless otherwise specified, the terms "first," "second," "third," etc. are used merely as labels and do not impose any order, position, or hierarchy requirements on the elements to which these terms refer. Furthermore, a reference to, for example, a "second" element does not require or exclude the presence of, for example, a "first" element or a lower ordinal element, and / or a "third" or higher ordinal element.

[0075] As used herein, when the phrase "at least one" is used in connection with a list of elements, it means that one or more of the listed elements may be used in various combinations, or that only one of the listed elements may be required. For example, "at least one of element A, element B, and element C" may include, but is not limited to, element A, or element A and element B. Also in this example, it may include elements A, element B, and element C, or element B and element C. In other examples, "at least one" may mean, but is not limited to, two elements A, one element B, and ten elements C, or four elements B and seven elements C, or any other suitable combination. As used herein, the phrase "and / or" and the symbol " / " include any and all combinations of one or more of the associated listed elements.

[0076] As used herein, the terms "coupled," "coupled," and similar terms refer to two or more elements being joined, coupled, fixed, attached, connected, in communication with, or otherwise associated with one another (e.g., mechanically, electrically, fluidly, optically, electromagnetically). In various examples, multiple elements may be directly or indirectly associated. For example, element A may be directly associated with element B. Element A may also be indirectly associated with element B through another element C. Note that not all associations between various disclosed elements are necessarily shown. Thus, other associations than those shown may exist.

[0077] As used herein, the term "about" refers to a condition that is not exactly the same as the described condition, but is close to the described condition and is capable of performing a desired function or achieving a desired result. For example, the term "about" refers to a condition that is within an acceptable range of a predetermined tolerance or precision, for example, a condition that is within 10% of the described condition. However, the term "about" does not exclude a condition that is exactly the same as the described condition. As used herein, the term "substantially" refers to a condition that is essentially the same as the described condition and is capable of performing a desired function or achieving a desired result.

[0078] The figures referenced in the above description, including Figures 1-7, 8A-B, 9-13, and 21, depict functional elements, functions, or components and do not necessarily imply a particular specific structure. Accordingly, modifications, additions, and / or omissions may be made to the depicted structures. Additionally, those skilled in the art will recognize that not all elements, functions, and / or components shown and described in Figures 1-7, 8A-B, 9-13, and 21 need be included in every example, and not all described elements, functions, and / or components may be shown in each illustrated example. Accordingly, some of the elements, functions, and / or components shown and described in Figures 1-7, 8A-B, 9-13, and 21 may be combined in various ways without including other features shown in Figures 1-7, 8A-B, 9-13, and 21, other figures, and / or the accompanying disclosure, without such combinations necessarily being explicitly stated in this disclosure. Similarly, additional features not limited to the described embodiments may be combined with some or all of the features shown and described herein. Unless otherwise noted, the schematic illustrations of the above-described embodiments shown in Figures 1-7, 8A-B, 9-13, and 21 are not intended to imply any architectural limitations on the exemplary embodiments. Rather, they illustrate one exemplary structure, which may be varied as appropriate. Thus, modifications, additions, and / or omissions may be made to the illustrated structure. Furthermore, elements, functions, and / or components serving similar, or at least substantially similar, purposes in Figures 1-7, 8A-B, 9-13, and 21 are labeled with the same reference numerals, and such elements, functions, and / or components may not be described in detail with reference to Figures 1-7, 8A-B, 9-13, and 21. Similarly, in Figures 1-7, 8A-B, 9-13, and 21, not all elements, features, and / or components are labeled with reference numerals, but the reference numerals associated with these elements may be used in the description for consistency.

[0079] In Figures 14-36 referenced in the above description, blocks may represent processes, steps, and / or portions thereof, and lines connecting various blocks do not necessarily imply a particular order or dependency of the processes or portions thereof. It should be noted that not all dependencies between the various processes disclosed are necessarily shown. Figures 14-36 and the accompanying disclosure describing the processes in the methods described herein do not necessarily dictate the order in which these processes are performed. Rather, an exemplary order is shown, but the order of these processes can be changed as appropriate. Therefore, modifications, additions, and / or omissions can be made to the illustrated processes, and some processes can be performed in a different order or simultaneously. Additionally, one skilled in the art will recognize that not all of the steps described need to be performed.

[0080] Furthermore, the use of features, advantages, or similar expressions in this specification does not imply that all features and advantages that can be realized in embodiments of the present disclosure should or are included in a single example. Rather, the description of features and advantages means that a particular feature, advantage, or characteristic described in connection with an example is included in at least one example. Thus, features, advantages, and similar expressions described in this disclosure may or may not refer to the same example.

[0081] Embodiments of the presently disclosed subject matter may be described in connection with an aircraft manufacturing and service method 3700 shown in FIG. 37 and an aircraft 3800 shown in FIG. 38 . In one or more examples, the disclosed wire assembly system 100 and methods 1400, 1500, 3000 for assembling electrical raceway modules can be used in aircraft manufacturing. Prior to production, the service method 3700 may include specification and design of the aircraft 3800 (block 3702) and material procurement (block 3704). During production, the aircraft 3800 undergoes component and subassembly manufacturing (block 3706) and system integration (block 3708). The aircraft 3800 then undergoes certification and delivery (block 3710) and enters service (block 3712). While in customer service, the aircraft 3800 undergoes routine maintenance and service (block 3714). Routine maintenance and upkeep may include upgrading, reconfiguring, modifying, etc., one or more systems of aircraft 3800.

[0082] Each step of maintenance method 3700 may be performed or implemented by a system integrator, a third party, and / or an operator (e.g., a customer). Note that a system integrator may include, but is not limited to, an aircraft manufacturer and any number of major system subcontractors. A third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers. An operator may be an airline, a leasing company, a military entity, a service organization, etc.

[0083] As shown in FIG. 38 , aircraft 3800 produced by maintenance method 3700 may include an airframe 3802 with a number of high-level systems 3804 and an interior 3806. Examples of high-level systems 3804 include one or more of a propulsion system 3808, an electrical system 3810, a hydraulic system 3812, and an environmental system 3814. The aircraft may also include any number of other systems. Additionally, while described with reference to the aerospace industry, the principles of the present disclosure may be applied to other industries, such as the automotive industry. Thus, in addition to aircraft 3800, the principles of the present disclosure may be applied to other vehicles, such as land vehicles, sea vessels, and spacecraft.

[0084] The disclosed wire assembly systems 100 and methods 1400, 1500, 3000 for assembling electrical raceway modules may be employed during any one or more stages of the manufacturing and service method 3700. For example, the components or subassemblies corresponding to component and subassembly manufacturing (block 3706) may be similarly manufactured or produced as components or subassemblies produced while the aircraft 3800 is in service (block 3712). Additionally, utilizing one or more embodiments of the above-described systems, methods, or combinations thereof during, for example, the manufacturing process (blocks 3706 and 3708) may substantially increase the speed or reduce the cost of assembling the aircraft 3800. Similarly, one or more embodiments implementing the above-described systems and methods, or combinations thereof, may be used during, for example, but not limited to, the in-service (block 3712) or maintenance and service (block 3714) processes of the aircraft 3800.

[0085] The features, advantages, and characteristics of any described embodiment may be combined in any suitable manner in one or more other embodiments. Those skilled in the art will appreciate that the embodiments described herein may be practiced without one or more of the specific features or advantages of a particular embodiment. In some cases, additional features and advantages may be recognized in certain embodiments, but these may not be present in all embodiments. Furthermore, while various embodiments of the wire assembly system 100 and methods 1400, 1500, and 3000 for assembling electrical raceway modules have been shown and described, modifications will occur to those skilled in the art upon reading this specification. The present application encompasses all such modifications and is limited only by the scope of the claims. <Additional Notes>

[0086] The present disclosure further includes the following notes: Appendix 1. A wire assembly system (100) for assembling an electrical raceway module, comprising: a raceway assembly tool (202) disposed on a top surface (204) of a work support structure (206); a wire shuttle subsystem (208) including 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); a system controller (220) capable of functionally communicating with the wire shuttle subsystem (208) and the at least one robotic manipulator (218) and controlling placement of a wire (300) from the first shuttle (210) and the second shuttle (216) to the raceway assembly tool (202). Appendix 2. 2. The wire assembly system of claim 1, wherein the electrical raceway module is configured to be incorporated into an end product as a modular component of the electrical raceway architecture for the end product. Appendix 3. 3. The wire assembly system of claim 2, wherein the end product comprises at least one of an aircraft, a rotorcraft, a bus, a passenger transport vehicle, a military transport vehicle, an operational 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. Appendix 4. 4. The wire assembly system of any one of claims 1 to 3, wherein the electrical raceway module has at least one of a width of about 4 inches to about 36 inches, a width of about 8 inches to about 24 inches, and a width of about 14 inches to about 18 inches. Appendix 5. 5. The wire assembly system of claim 1, wherein the electrical raceway module has at least one of a length of about 2 feet to about 100 feet, a length of about 10 feet to about 80 feet, a length of about 20 feet to about 60 feet, a length of about 30 feet to about 50 feet, and a length of about 40 feet. Appendix 6. 6. The wire assembly system according to any one of claims 1 to 5, wherein the work support structure (206) includes a transport table. Appendix 7. 7. The wire assembly system of claim 6, wherein the transport table includes at least one of a movable cart, a table with rollers on its upper surface, and a support structure having a transport belt. Appendix 8. 8. The wire assembly system of any one of claims 1 to 7, wherein the at least one robotic manipulator (218) comprises one or more of at least one robotic arm, at least one four-axis robotic arm, at least one six-axis robotic arm, at least one seven-axis robotic arm, at least one selectively compliant articulated robotic arm, at least one collaborative robot, at least one electromechanical manipulator, at least one automated mechanical manipulator, at least one semi-automated mechanical manipulator, at least one working robot with fixed actuators, and at least one semi-manual robot. Appendix 9. A wire assembly system as described in any one of appendixes 1 to 8, wherein the wire assembly system (100) is configured to receive the wire (300) on a wire carrier (400) from a wire preparation system (102) via a wire conveying system (104). Appendix 10. 10. The wire assembly system of claim 9, wherein the wire carrier (400) includes at least one coil holder (402), a first end clamp (404), a second end clamp (406), and a wire carrier identification element (408). Appendix 11. 11. The wire assembly system of claim 10, wherein the wire carrier identification element (408) includes 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. Appendix 12. The wire (300), in a received state, includes a coil (302) having a branch point (304) at which a first end (306) of the wire (300) and a second end (308) of the wire (300) branch off from the coil (302); A wire assembly system as described in any one of Appendices 9 to 11, wherein the wire (300) further includes a first wire marker (310) provided near the first end portion (306) and a second wire marker (312) provided near the second end portion (308). Appendix 13. 13. A wire assembly system according to any one of appendices 9 to 12, wherein the wire (300) comprises at least one of a single wire, a twisted pair wire, a multi-core cable, a shielded cable, an unarmored cable, a coaxial cable, a matched impedance cable, and an optical fiber cable. Appendix 14. The raceway assembly tool (202) comprises: a raceway framework (502) including a plurality of longitudinal side plates (504), a plurality of lateral end plates (506), longitudinal support members (508) disposed between the lateral end plates (506), and lateral support members (510) disposed between the longitudinal side plates (504); an electrical connector (512) located adjacent said lateral end plate (506); and a wire routing support (514) attached to the lateral support member (510) to form a longitudinal wiring lane (516). Appendix 15. 15. The wire assembly system of claim 14, wherein the electrical connector (512) comprises at least one of a modular connector and a standard connector. Appendix 16. The raceway assembly tool (202) further comprises: at least one additional electrical connector (518) located adjacent at least one of said longitudinal side panels (504); at least one printed wiring board (520) mounted to at least one of one or more of the longitudinal side panels (504), one or more of the lateral end panels (506), one or more of the longitudinal support members (508), and one or more of the lateral support members (510); and a branch wiring support (522) attached to the lateral support member (510) to form a lateral wiring lane (524) branching from one or more of the vertical wiring lanes (516). Appendix 17. the first shuttle (210) is configured to receive and temporarily hold a first end (306) of the wire (300), and the second shuttle (216) is configured to receive and temporarily hold a second end (308) of the wire (300); 17. The wire assembly system of any one of claims 1 to 16, wherein the system controller (220) and the wire shuttle subsystem (208) are configured to position the first shuttle (210) and the second shuttle (216) to extend the wire (300) longitudinally on the upper surface (212) of the tool support structure (214). Appendix 18. 18. The wire assembly system of claim 17, wherein the system controller (220), the wire shuttle subsystem (208), and the at least one robotic manipulator (218) are configured to position the wire (300) having the first end (306) and the second end (308) at a predetermined position in the raceway assembly tool (202). Appendix 19. The at least one robotic manipulator (218) at least one transfer robot manipulator (602) mounted on the upper surface (212) of the tool support structure (214); 19. The wire assembly system of claim 17 or 18, wherein the at least one transfer robot manipulator (602) is configured to pick up the wire (300) from between the first shuttle (210) and the second shuttle (216) and place the wire (300) in a predetermined position on one or more wire routing supports (514) in the raceway assembly tool (202). Appendix 20. 20. The wire assembly system of claim 19, wherein the at least one transfer robot manipulator (602) includes one or more of at least one robot arm, at least one selectively compliant articulated robot arm, and at least one collaborative robot. Appendix 21. 21. The wire assembly system of claim 19 or 20, wherein the at least one transfer robot manipulator (602) comprises a plurality of transfer robot manipulators (602) spaced apart vertically along the upper surface (212) of the tool support structure (214). Appendix 22. 22. The wire assembly system of claim 21, wherein the plurality of transfer robot manipulators (602) are spaced apart by at least one of about 1 foot to about 2 feet, about 2 feet to about 3 feet, and about 3 feet to about 4 feet. Appendix 23. The at least one robotic manipulator (218) at least one insertion robot manipulator (604) disposed on the upper surface (212) of the tool support structure (214); 23. The wire assembly system of any one of appendices 17 to 22, wherein the at least one insertion robot manipulator (604) is configured to pick up the first terminal end (306) of the wire (300) from the first shuttle (210) and insert the first terminal end (306) into a predetermined starting electrical connector (512) at a first predetermined position of the raceway assembly tool (202). Appendix 24. 24. The wire assembly system of claim 23, wherein the at least one insertion robot manipulator (604) comprises one or more of at least one robot arm, at least one six-axis robot arm, at least one seven-axis robot arm, and at least one collaborative robot. Appendix 25. 25. The wire assembly system of claim 23 or 24, wherein the at least one insertion robot manipulator (604) is configured to pick up the second terminal end (308) of the wire (300) from the second shuttle (216) and insert the second terminal end (308) into a predetermined terminal electrical connector (512) at a second predetermined position of the raceway assembly tool (202). Appendix 26. The at least one robotic manipulator (218) a first insertion robotic manipulator (606) and a second insertion robotic manipulator (610); the first insertion robot manipulator (606) is mounted to a first robot transport unit (608) disposed on the upper surface (212) of the tool support structure (214), the first robot transport unit configured to translate the first insertion robot manipulator (606) along the length of the raceway assembly tool (202); the first insertion robot manipulator (606), in conjunction with the first robot transport unit (608), is configured to pick up the first terminal end (306) of the wire (300) from the first shuttle (210) and insert the first terminal end (306) into a predetermined originating electrical connector (512) at a first predetermined position of the raceway assembly tool (202); the second insertion robot manipulator (610) is mounted to a second robot transport unit (612) positioned on the upper surface (212) adjacent to the first robot transport unit (608), the second robot transport unit configured to translate the second insertion robot manipulator (610) along the length of the raceway assembly tool (202); The wire assembly system described in any one of Appendixes 17 to 25, wherein the second insertion robot manipulator (610) is configured to work in conjunction with the second robot transport unit (612) to pick up the second terminal end portion (308) of the wire (300) from the second shuttle (216) and insert the second terminal end portion (308) into a predetermined end-side electrical connector (512) at a second predetermined position of the raceway assembly tool (202). Appendix 27. The wire shuttle subsystem (208) further comprises: a longitudinal groove (702) disposed on the upper surface (212) of the tool support structure (214) and extending along the raceway assembly tool (202); a first transport assembly (704) mechanically connected to the first shuttle (210) and configured to position the first shuttle (210) along a first longitudinal rail (706) of the longitudinal channel (702); a second transport assembly (708) mechanically connected to the second shuttle (216) and configured to position the second shuttle (216) along a second longitudinal rail (710) of the longitudinal channel (702); an unwinding assembly (712) disposed on the upper surface (212) of the tool support structure (214) and configured to hold the coil (302) of the wire (300), the first end (306) of the wire (300), and the second end (308) of the wire (300); an image sensor (714) disposed adjacent the unwinding assembly (712) and configured to selectively acquire images of the first end (306) and the second end (308) and images indicative of the condition of the coil (302) at the unwinding assembly (712); a wire carrier identification detector (715) disposed adjacent a wire carrier (400) in a wire transport system (104), the wire carrier (400) configured to transport the wire (300) from a wire preparation system (102) to the wire assembly system (100); a wire carrier identification detector (715) configured to selectively obtain an identification number from a wire carrier identification element (408) on the wire carrier (400); a sensor in functional communication with the first transport assembly (704), the second transport assembly (708), the unwind assembly (712), the image sensor (714), the wire carrier identification detector (715), and the system controller (220); and a control assembly (716) that controls the movement of the first end portion (306) from the unwinding assembly (712) to the first shuttle (210), the movement of the first shuttle (210) along the first longitudinal rail (706), the unwinding of the coil (302) from the unwinding assembly (712), the placement of the second end portion (308) from the unwinding assembly (712) to the second shuttle (216), and the movement of the second shuttle (216) along the second longitudinal rail (710). Appendix 28. 28. The wire assembly system of claim 27, wherein the first conveying assembly (704) includes 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. Appendix 29. 29. The wire assembly system of claim 27 or 28, wherein the second conveying assembly (708) includes 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. Appendix 30. 30. The wire assembly system of any one of claims 27 to 29, wherein the image sensor (714) includes at least one of a digital camera, a charge-coupled device, an active pixel device, an optical scanner, and a laser scanner. Appendix 31. 31. The wire assembly system of any one of claims 27 to 30, wherein the wire carrier identification detector (715) includes 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. Appendix 32. The unwinding assembly (712) a rotating plate (718) configured to temporarily hold the coil (302) of the wire (300) and unwind the wire (300) under tension at the first end (306) in conjunction with movement of the first shuttle (210) along the first longitudinal rail (706) of the wire shuttle subsystem (208); a first end holder (720) disposed adjacent the rotating plate (718) and configured to temporarily hold the first terminal end (306) of the wire (300); A wire assembly system as described in any of Appendixes 27 to 31, comprising: a second end holder (722) attached to the rotating plate (718) and configured to hold the second terminal end (308) of the wire (300). Appendix 33. 33. The wire assembly system of claim 32, wherein the first end holder (720) includes the first shuttle (210) when positioned on the first longitudinal rail (706) of the longitudinal groove (702) provided near the rotating plate (718). Appendix 34. 34. The wire assembly system of claim 32 or 33, further comprising a work robot manipulator (614) mounted on a support platform (616) adjacent to a proximal end region (618) of the tool support structure (214), wherein the work robot manipulator (614) is configured to pick up the coil (302), the first end portion (306), and the second end portion (308) of the wire (300) from a wire carrier (400) in a wire transport system (104), place the coil (302) on the rotating plate (718) of the unwinding assembly (712), place the first end portion (306) on the first end holder (720), and place the second end portion (308) on the second end holder (722). Appendix 35. 35. The wire assembly system of claim 34, wherein the working robot manipulator (614) comprises at least one of a robotic arm, a six-axis robotic arm, a collaborative robot, an electromechanical manipulator, an automated mechanical manipulator, a semi-automated mechanical manipulator, a working robot with fixed actuators, and a semi-manual robot. Appendix 36. the system controller (220) and the work robot manipulator (614) are configured to pick up the first terminal end (306) of the wire (300) from the first end holder (720) and place the first terminal end (306) on the first shuttle (210); 36. The wire assembly system of claim 34 or 35, wherein the system controller (220) and the work robot manipulator (614) are configured to pick up the second end portion (308) of the wire (300) from the second end holder (722) and place the second end portion (308) on the second shuttle (216) when the system controller (220) detects that the wire (300) has been unwound from the rotating plate (718). Appendix 37. 1. A method (1400) for assembling an electrical raceway module, comprising: receiving (1402) the raceway assembly tool (202) from the raceway preparation area (106) at a work support structure (206), wherein the work support structure (206) is positioned alongside a tool support structure (214); receiving (1404) a wire (300) for placement in the raceway assembly tool (202) from a wire preparation system (102), wherein the wire (300) includes a first end portion (306) and a second end portion (308); positioning (1406) the wire (300) on the upper surface (212) of the tool support structure (214) between a first shuttle (210) holding the first end (306) and a second shuttle (216) holding the second end (308); picking up (1408) the wire (300) having the first end (306) and the second end (308) from the upper surface (212) of the tool support structure (214), the first shuttle (210), and the second shuttle (216); placing (1410) the wire (300) in a predetermined position in the raceway assembly tool (202). Appendix 38. 38. The method of claim 37, wherein the electrical raceway module is configured to be incorporated into an end product as a modular component of an electrical raceway architecture for the end product. Appendix 39. 39. The method of claim 38, wherein the end product comprises at least one of an aircraft, a rotorcraft, an unmanned aerial vehicle, a bus, a passenger transport vehicle, a military transport vehicle, an operational military vehicle, a passenger ship, a cargo ship, a naval vessel, a commercial building, and a residential building. Appendix 40. 40. The method of any one of claims 37-39, wherein the electrical raceway module has at least one of a width of about 4 inches to about 36 inches, a width of about 8 inches to about 24 inches, and a width of about 14 inches to about 18 inches. Appendix 41. 41. The method of any of claims 37-40, wherein the electrical raceway module has at least one of a length of about 2 feet to about 100 feet, a length of about 10 feet to about 80 feet, a length of about 20 feet to about 60 feet, a length of about 30 feet to about 50 feet, and a length of about 40 feet. Appendix 42. 42. The method according to any one of claims 37 to 41, wherein the workpiece support structure (206) includes a transport table. Appendix 43. 43. The method of claim 42, wherein the transport table includes at least one of a mobile cart, a table with rollers on its upper surface, and a support structure having a transport belt. Appendix 44. 44. The method of any of claims 37 to 43, wherein the method is implemented in a wire assembly system (100) configured to receive the wire (300) on a wire carrier (400) from a wire preparation system (102) via a wire transport system (104). Appendix 45. The wire (300), in a received state, includes a coil (302) having a branch point (304) at which a first end (306) of the wire (300) and a second end (308) of the wire (300) branch off from the coil (302); 45. The method of claim 44, wherein the wire (300) further includes a first wire marker (310) located near the first end portion (306) and a second wire marker (312) located near the second end portion (308). Appendix 46. 46. ​​The method of claim 44 or 45, wherein the wire (300) comprises at least one of a solid wire, a twisted pair, a multi-core cable, a shielded cable, an unarmored cable, a coaxial cable, a matched impedance cable, and a fiber optic cable. Appendix 47. 47. A method (1500) according to any one of claims 37 to 46, further comprising repeating (1502) the receiving (1402, 1404), positioning (1406), picking up (1408), and placing (1410) of the wire (300) for the next wire (300) until all wires designated for autonomous placement in the raceway assembly tool (202) have been placed. Appendix 48. 48. The method of claim 47, further comprising transporting the raceway assembly tool (202) to a post-wire assembly area (108) to prepare the electrical raceway module for attachment to an end product, and performing manual assembly operations (1504) on the raceway assembly tool (202). Appendix 49. The raceway assembly tool (202) receiving (1402) receiving (1602) the raceway assembly tool (202) from the raceway preparation area (106) via a raceway transport system; transferring (1604) the raceway assembly fixture (202) from the raceway transport system to the top surface (204) of the workpiece support structure (206); moving (1606) the work support structure (206) having the raceway assembly tool (202) alongside the tool support structure (214); 49. The method (1400) of any one of claims 37 to 48, including fixing (1608) the work support structure (206) in place. Appendix 50. The raceway assembly tool (202) receiving (1402) transporting (1702) the raceway assembly tool (202) from the raceway preparation area (106) onto the work support structure (206); moving (1704) the work support structure (206) having the raceway assembly tool (202) alongside the tool support structure (214); 50. The method of any of claims 37 to 49, comprising fixing (1706) the work support structure (206) in place. Appendix 51. The receiving portion (1404) of the wire (300) is using a work robot manipulator (614) mounted on a support platform (616) adjacent a proximal end region (618) of the tool support structure (214) to pick up (1802) the coil (302) of wire (300) having the first end (306) and the second end (308) from a wire carrier (400) in a wire transport system (104); 51. A method according to any one of claims 37 to 50, comprising using the work robot manipulator (614) to place (1804) the coil (302), the first end portion (306), and the second end portion (308) onto an unwinding assembly (712) disposed on the upper surface (212) at the proximal end region (618) of the tool support structure (214). Appendix 52. The pickup (1802) of the coil (302) is picking up (1902) the coil (302) of the wire (300) from at least one coil holder (402) of the wire carrier (400) using at least one first holding device (2102) of an end effector (2100) attached to the work robot manipulator (614); using a second holding device (2104) of the end effector (2100) to pick up (1904) the first terminal end (306) of the wire (300) from the first end clamp (404) of the wire carrier (400); 52. The method of claim 51, comprising using a third holding device (2106) of the end effector (2100) to pick up (1906) the second end portion (308) of the wire (300) from a second end clamp (406) of the wire carrier (400). Appendix 53. The arrangement (1804) of the coil (302) is placing (2002) the coil (302) of the wire (300) onto a rotating plate (718) of the unwinding assembly (712) from at least one first holding device (2102) of an end effector (2100) attached to the work robot manipulator (614); placing (2004) the first terminal end (306) of the wire (300) from the second holding device (2104) of the end effector (2100) into a first end holder (720) of the unwind assembly (712); The method described in Appendix 51 or 52, comprising placing (2006) the second terminal end (308) of the wire (300) from a third holding device (2106) of the end effector (2100) into a second end holder (722) of the unwinding assembly (712). Appendix 54. 54. The method of claim 53, wherein the first end holder (720) includes the first shuttle (210) when positioned adjacent the rotating plate (718). Appendix 55. a coil (302) of the wire (300) having the first end (306) and the second end (308) is disposed on an unwinding assembly (712) disposed on the upper surface (212) at the proximal end region (618) of the tool support structure (214); The positioning (1406) of the wire (300) is obtaining (2202) an identification number from a wire carrier identification element (408) on a wire carrier (400) of the wire transport system (104); In this case, the identification number uniquely identifies the wire carrier (400) with respect to other wire carriers in the wire transport system (104), the identification number corresponds to a unique wire number assigned to the wire (300) relative to other wires in the electrical raceway module; determining (2204) locations within the raceway assembly tool (202) for placing the wire (300), the first end (306) of the wire (300), and the second end (308) of the wire (300) based at least in part on the identification number; moving (2206) the first shuttle (210) along a first longitudinal rail (706) to a first pickup position adjacent the unwind assembly (712); placing (2208) the first terminal end (306) of the wire (300) onto the first shuttle (210) using a work robot manipulator (614) mounted on a support platform (616) adjacent the proximal end region (618) of the tool support structure (214); moving (2210) the first shuttle (210) away from the unwinding assembly (712) while holding the first terminal end (306), and rotating a rotating plate (718) of the unwinding assembly (712) until the coil (302) of the wire (300) is unwound; moving (2212) the second shuttle (216) along a second longitudinal rail (710) to a second pickup position adjacent the unwind assembly (712); using a work robot manipulator (614) to place (2214) the second terminal end (308) of the wire (300) from a second end holder (722) of the unwind assembly (712) onto the second shuttle (216); A method according to any one of claims 37 to 54, comprising moving (2216) the first shuttle (210) having the first end (306) and the second shuttle (216) having the second end (308) away from the unwinding assembly (712) until the wire (300) is positioned along the target position of the wire (300) in the raceway assembly tool (202). Appendix 56. The movement (2210) of the first shuttle (210) and the rotation of the rotating plate (718) are acquiring (2302) a series of visual images of the rotating plate (718) while the coil (302) of the wire (300) is being unwound; determining (2304) whether the coil (302) of wire (300) has unwound from the rotating plate (718) based at least in part on the series of visual images; 56. The method of claim 55, comprising stopping (2306) the movement (2210) of the first shuttle (210) and the rotation of the rotating plate (718) when the coil (302) is unwound. Appendix 57. 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) are After the wire (300) is positioned along the target position of the wire (300), the movement (2216) of the first shuttle (210) and the second shuttle (216) is stopped (2402); Slowly moving (2404) the first shuttle (210) away from the target location of the wire (300); Slowly moving (2406) the second shuttle (216) away from the target location of the wire (300); stopping (2408) the reverse movement of the first shuttle (210) and the second shuttle (216) when at least one of the first force sensor (724) and the second force sensor (726) detects that the tension in the wire (300) exceeds a predetermined tension threshold; 57. The method of claim 55 or 56, comprising retracting (2410) the first shuttle (210) and the second shuttle (216) a predetermined amount to remove tension and center the first end (306) of the wire (300) and the second end (308) of the wire (300) relative to the target position of the wire (300). Appendix 58. 58. The method of claim 57, wherein the predetermined tension threshold comprises at least one of about 1 lb. to about 5 lb. tension, about 2 lb. to about 4 lb. tension, and about 3 lb. tension. Appendix 59. 59. The method of claim 57 or 58, wherein the predetermined amount of retraction of the wire (300) toward the target position includes at least one of about 0.1% to about 0.7% of the length of the wire (300), about 0.2% to about 0.6% of the length of the wire (300), about 0.3% to about 0.5% of the length of the wire (300), and about 0.4% of the length of the wire (300). Appendix 60. The pickup (1408) of the wire (300) A first insertion robot manipulator (606) in a first robot transport unit (608) is moved (2502) toward the first shuttle (210), the first insertion robot manipulator (606) is attached to the first robot transport unit (608), the first robot transport unit (608) is disposed on the upper surface (212) of the tool support structure (214); using the first insertion robot manipulator (606) to pick up (2504) the first end (306) of the wire (300) from the first shuttle (210); moving (2506) a second insertion robot manipulator (610) on a second robot transport unit (612) toward the second shuttle (216), wherein the second insertion robot manipulator (610) is attached to the second robot transport unit (612), and the second robot transport unit (612) is positioned on the upper surface (212) of the tool support structure (214) adjacent to the first robot transport unit (608); using the second insertion robot manipulator (610) to pick up (2508) the second end (308) of the wire (300) from the second shuttle (216); A method according to any one of appendices 37 to 59, comprising using at least one transfer robot manipulator (602) attached to the upper surface (212) of the tool support structure (214) adjacent to the first robot transport unit (608) or the second robot transport unit (612) to pick up (2510) a portion of the wire (300) between the first end (306) and the second end (308). Appendix 61. 61. The method of claim 60, wherein a plurality of transfer robot manipulators (602) between the first end (306) of the wire (300) and the second end (308) of the wire (300) are spaced apart at predetermined distances along the top surface (212) of the tool support structure (214). Appendix 62. 62. The method of claim 61, wherein the predetermined distance comprises at least one of about 1 foot to about 3 feet, about 1.5 feet to about 2.5 feet, and about 2 feet. Appendix 63. The arrangement (1410) of the wires (300) is using at least one transfer robot manipulator (602) mounted on the upper surface (212) of the tool support structure (214) adjacent to a first robotic transport unit (608) associated with a first insertion robot manipulator (606) or a second robotic transport unit (612) associated with a second insertion robot manipulator (610), to place (2602) a portion of the wire (300) between the first end (306) and the second end (308) onto a wire routing support (514) of a predetermined longitudinal routing lane (516) within the raceway assembly tool (202); the first insertion robot manipulator (606) is attached to the first robot transport unit (608), the first robot transport unit (608) is disposed on the upper surface (212) of the tool support structure (214); the second insertion robot manipulator (610) is attached to the second robot transport unit (612), and the second robot transport unit (612) is disposed on the upper surface (212) of the tool support structure (214); placing (2604) the first termination (306) of the wire (300) into a predetermined starting electrical connector (512) on the raceway assembly tool (202) using the first insertion robot manipulator (606); A method as described in any of appendices 37 to 62, including using the second insertion robot manipulator (610) to place (2606) the second terminal end (308) of the wire (300) into a predetermined terminal electrical connector (512) in the raceway assembly tool (202). Appendix 64. 64. The method of claim 63, wherein a plurality of transfer robot manipulators (602) between the first end (306) of the wire (300) and the second end (308) of the wire (300) are spaced apart at predetermined distances along the top surface (212) of the tool support structure (214). Appendix 65. 65. The method of claim 64, wherein the predetermined distance comprises at least one of about 1 foot to about 3 feet, about 1.5 feet to about 2.5 feet, and about 2 feet. Appendix 66. The pick-up (1408) of the wire (300) and the placement (1410) of the wire (300) are using a robotic manipulator (218) mounted on the upper surface (212) of the tool support structure (214) to pick up (2702) a portion of the wire (300) between the first end (306) and the second end (308); A method as described in any of claims 37 to 65, including using the robotic manipulator (218) to position (2704) a portion of the wire (300) between the first end (306) and the second end (308) on a wire routing support (514) of a predetermined vertical wiring lane (516) within the raceway assembly tool (202). Appendix 67. The wire (300) pickup (1408) and the wire (300) placement (1410) further include: The robot manipulator (218) in the robot transfer unit (608, 612) is moved (2802) toward the first shuttle (210), and The robot manipulator (218) is attached to the robot transport unit (608, 612); the robot transport units (608, 612) are disposed on the upper surface (212) of the tool support structure (214); using the robotic manipulator (218) to pick up (2804) the first end (306) of the wire (300) from the first shuttle (210); 67. The method of claim 66, comprising using the robotic manipulator (218) to place (2806) the first end (306) of the wire (300) into a predetermined starting electrical connector (512) in the raceway assembly tool (202). Appendix 68. The wire (300) pickup (1408) and the wire (300) placement (1410) further include: moving (2902) the robot manipulator (218) of the robot transport unit (608, 612) toward the second shuttle (216); using the robotic manipulator (218) to pick up (2904) the second end (308) of the wire (300) from the second shuttle (216); 68. The method of claim 67, comprising using the robotic manipulator (218) to place (2906) the second end portion (308) of the wire (300) into a predetermined terminal electrical connector (512) in the raceway assembly tool (202). Appendix 69. 1. A method (3000) for assembling an electrical raceway module, comprising: receiving (3002) the raceway assembly tool (202) from the raceway preparation area (106) at a work support structure (206), wherein the work support structure (206) is positioned alongside a tool support structure (214); receiving (3004) a wire (300) for placement in the raceway assembly tool (202) from a wire preparation system (102), wherein the wire (300) includes a first end portion (306) and a second end portion (308); positioning (3006) the wire (300) on the upper surface (212) of the tool support structure (214) between a first shuttle (210) holding the first end (306) and a second shuttle (216) holding the second end (308); picking up (3008) the wire (300) having the first end (306) and the second 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 wire (300) in a predetermined position in the raceway assembly tool (202); repeating (3012) the receiving (3002, 3004), positioning (3006), picking up (3008), and placing (3010) of the wire (300) for the next wire (300) until all wires designated for autonomous placement in the raceway assembly tool (202) have been placed; transporting the raceway assembly tool (202) to a post-wire assembly area (108) to prepare the electrical raceway module for attachment to an end product, and performing manual assembly operations (3014) on the raceway assembly tool (202). Appendix 70. The raceway assembly tool (202) receiving (3002) receiving (3102) the raceway assembly tool (202) from the raceway preparation area (106) via a raceway transport system; transferring (3104) the raceway assembly fixture (202) from the raceway transport system to the top surface (204) of the workpiece support structure (206); moving (3106) the work support structure (206) having the raceway assembly tool (202) alongside the tool support structure (214); 70. The method of claim 69, including fixing (3108) the work support structure (206) in place. Appendix 71. The receiving portion (3004) of the wire (300) is using a work robot manipulator (614) mounted on a support platform (616) adjacent a proximal end region (618) of the tool support structure (214) to pick up (3202) the coil (302) of wire (300) having the first end portion (306) and the second end portion (308) from a wire carrier (400) in a wire transport system (104); 71. The method of claim 69 or 70, comprising using the work robot manipulator (614) to place (3204) the coil (302), the first end portion (306), and the second end portion (308) onto an unwinding assembly (712) disposed on the upper surface (212) at the proximal end region (618) of the tool support structure (214). Appendix 72. a coil (302) of the wire (300) having the first end (306) and the second end (308) is disposed on an unwinding assembly (712) disposed on the upper surface (212) at the proximal end region (618) of the tool support structure (214); The positioning (3006) of the wire (300) is obtaining (3302) an identification number from a wire carrier identification element (408) on a wire carrier (400) of the wire transport system (104); In this case, the identification number uniquely identifies the wire carrier (400) with respect to other wire carriers in the wire transport system (104), the identification number corresponds to a unique wire number assigned to the wire (300) relative to other wires in the electrical raceway module; determining (3304) a location within the raceway assembly tool (202) for placing the wire (300), the first end (306) of the wire (300), and the second end (308) of the wire (300) based at least in part on the identification number; moving (3306) the first shuttle (210) along a first longitudinal rail (706) to a first pickup position adjacent the unwind assembly (712); placing (3308) the first terminal end (306) of the wire (300) onto the first shuttle (210) using a work robot manipulator (614) mounted on a support platform (616) adjacent the proximal end region (618) of the tool support structure (214); moving (3310) the first shuttle (210) away from the unwinding assembly (712) while holding the first terminal end (306), and rotating a rotating plate (718) of the unwinding assembly (712) until the coil (302) of the wire (300) is unwound; moving (3312) the second shuttle (216) along a second longitudinal rail (710) to a second pickup position adjacent the unwind assembly (712); using a work robot manipulator (614) to place (3314) the second terminal end (308) of the wire (300) from a second end holder (722) of the unwind assembly (712) onto the second shuttle (216); A method according to any one of claims 69 to 71, comprising moving (3316) the first shuttle (210) having the first end (306) and the second shuttle (216) having the second end (308) away from the unwinding assembly (712) until the wire (300) is positioned along the target position of the wire (300) in the raceway assembly tool (202). Appendix 73. The pickup (3008) of the wire (300) A first insertion robot manipulator (606) in a first robot transport unit (608) is moved (3402) toward the first shuttle (210), the first insertion robot manipulator (606) is attached to the first robot transport unit (608), the first robot transport unit (608) is disposed on the upper surface (212) of the tool support structure (214); using the first insertion robot manipulator (606) to pick up (3404) the first end (306) of the wire (300) from the first shuttle (210); moving (3406) a second insertion robot manipulator (610) on a second robot transport unit (612) toward the second shuttle (216), wherein the second insertion robot manipulator (610) is attached to the second robot transport unit (612), and the second robot transport unit (612) is positioned on the upper surface (212) of the tool support structure (214) adjacent to the first robot transport unit (608); using the second insertion robot manipulator (610) to pick up (3408) the second end (308) of the wire (300) from the second shuttle (216); A method according to any of claims 69 to 72, comprising using at least one transfer robot manipulator (602) attached to the upper surface (212) of the tool support structure (214) adjacent to the first robot transport unit (608) or the second robot transport unit (612) to pick up (3410) a portion of the wire (300) between the first end (306) and the second end (308). Appendix 74. The arrangement (3010) of the wires (300) is using at least one transfer robot manipulator (602) mounted on the upper surface (212) of the tool support structure (214) adjacent to a first robotic transport unit (608) associated with a first insertion robot manipulator (606) or a second robotic transport unit (612) associated with a second insertion robot manipulator (610), to place (3502) a portion of the wire (300) between the first end (306) and the second end (308) onto a wire routing support (514) of a predetermined longitudinal routing lane (516) within the raceway assembly tool (202); the first insertion robot manipulator (606) is attached to the first robot transport unit (608), the first robot transport unit (608) is disposed on the upper surface (212) of the tool support structure (214); the second insertion robot manipulator (610) is attached to the second robot transport unit (612), and the second robot transport unit (612) is disposed on the upper surface (212) of the tool support structure (214); placing (3504) the first termination (306) of the wire (300) into a predetermined starting electrical connector (512) on the raceway assembly tool (202) using the first insertion robot manipulator (606); A method as described in any of appendices 69 to 73, including using the second insertion robot manipulator (610) to place (3506) the second terminal end (308) of the wire (300) into a predetermined terminal electrical connector (512) in the raceway assembly tool (202). Appendix 75. The pickup (3008) of the wire (300) and the placement (3010) of the wire (300) are using a robotic manipulator (218) mounted on the upper surface (212) of the tool support structure (214) to pick up (3602) a portion of the wire (300) between the first end (306) and the second end (308); using the robotic manipulator (218) to place (3604) a portion of the wire (300) between the first end (306) and the second end (308) on a wire routing support (514) of a predetermined longitudinal routing lane (516) within the raceway assembly tool (202); The robot manipulator (218) in the robot transport unit (608, 612) is moved (3606) toward the first shuttle (210), and The robot manipulator (218) is attached to the robot transport unit (608, 612); the robot transport units (608, 612) are disposed on the upper surface (212) of the tool support structure (214); using the robotic manipulator (218) to pick up (3608) the first end (306) of the wire (300) from the first shuttle (210); Using the robotic manipulator (218), position (3610) the first terminal end (306) of the wire (300) at a predetermined starting electrical connector (512) on the raceway assembly tool (202); moving (3612) the robot manipulator (218) of the robot transport unit (608, 612) toward the second shuttle (216); using the robotic manipulator (218) to pick up (3614) the second end (308) of the wire (300) from the second shuttle (216); A method as described in any of appendices 69 to 74, including using the robotic manipulator (218) to place (3616) the second terminal end (308) of the wire (300) into a predetermined terminal electrical connector (512) in the raceway assembly tool (202).

Claims

1. 1. A wire assembly system for assembling an electrical raceway module, comprising: a raceway assembly tool disposed on the top surface of the work support structure; a wire shuttle subsystem including a first shuttle disposed on an upper surface of the tool support structure and a second shuttle disposed on the upper surface; at least one robotic manipulator disposed on the top surface of the tool support structure; a system controller in operative communication with the wire shuttle subsystem and the at least one robotic manipulator, the system controller controlling placement of wire from the first shuttle and the second shuttle into the raceway assembly tool.

2. the electrical raceway module is configured to be incorporated into an end product as a modular component of an electrical raceway architecture for the end product; 10. The wire assembly system of claim 1, wherein the end product comprises at least one of an aircraft, a rotorcraft, a bus, a passenger transport vehicle, a military transport vehicle, an operational 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.

3. the electrical raceway module has at least one of a width of about 4 inches to about 36 inches, a width of about 8 inches to about 24 inches, and a width of about 14 inches to about 18 inches; 10. The wire assembly system of claim 1, wherein the electrical raceway module has at least one of a length of about 2 feet to about 100 feet, a length of about 10 feet to about 80 feet, a length of about 20 feet to about 60 feet, a length of about 30 feet to about 50 feet, and a length of about 40 feet.

4. the workpiece support structure includes a transport table; 10. The wire assembly system of claim 1, wherein the transport table comprises at least one of a mobile cart, a table with rollers on its upper surface, and a support structure having a transport belt.

5. 10. The wire assembly system of claim 1, wherein the at least one robotic manipulator comprises one or more of at least one robotic arm, at least one four-axis robotic arm, at least one six-axis robotic arm, at least one seven-axis robotic arm, at least one selectively compliant articulated robotic arm, at least one collaborative robot, at least one electromechanical manipulator, at least one automated mechanical manipulator, at least one semi-automated mechanical manipulator, at least one work robot with fixed actuators, and at least one semi-manual robot.

6. the wire assembly system is configured to receive the wire on a wire carrier from a wire preparation system via a wire transport system, the wire carrier including at least one coil holder, a first end clamp, a second end clamp, and a wire carrier identification element; The wire assembly system of claim 1 , wherein the wire carrier identification element 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.

7. 7. The wire assembly system of claim 6, wherein the wire, when received, includes a coil having a branch point, at which a first end of the wire and a second end of the wire branch off from the coil, and the wire further includes a first wire marker located near the first end and a second wire marker located near the second end.

8. 7. The wire assembly system of claim 6, wherein the wire comprises at least one of a solid wire, a twisted pair, a multi-conductor cable, a shielded cable, an unarmored cable, a coaxial cable, a matched impedance cable, and a fiber optic cable.

9. The raceway assembly tool includes: a raceway framework including a plurality of longitudinal side plates, a plurality of lateral end plates, longitudinal support members disposed between the lateral end plates, and lateral support members disposed between the longitudinal side plates; an electrical connector disposed adjacent the lateral end plate; 10. The wire assembly system of claim 1, further comprising: wire routing supports attached to said lateral support members to define longitudinal routing lanes.

10. The wire assembly system of claim 9 , wherein the electrical connector comprises at least one of a modular connector and a standard connector.

11. The raceway assembly tool further comprises: at least one additional electrical connector disposed adjacent at least one of the longitudinal side panels; at least one printed wiring board mounted to at least one of the one or more of the longitudinal side panels, the one or more of the lateral end panels, the one or more of the longitudinal support members, and the one or more of the lateral support members; and branch wiring supports attached to the lateral support members to form lateral wiring lanes branching from one or more of the longitudinal wiring lanes.

12. the first shuttle is configured to receive and temporarily hold a first end portion of a wire, and the second shuttle is configured to receive and temporarily hold a second end portion of the wire; 2. The wire assembly system of claim 1, wherein the system controller and the wire shuttle subsystem are configured to position the first shuttle and the second shuttle to extend the wire longitudinally on the top surface of the tool support structure.

13. 13. The wire assembly system of claim 12, wherein the system controller, the wire shuttle subsystem, and the at least one robotic manipulator are configured to place the wire having the first end and the second end at a predetermined position in the raceway assembly tool.

14. The at least one robotic manipulator 13. The wire assembly system of claim 12, including at least one transfer robotic manipulator mounted on the upper surface of the tool support structure, the at least one transfer robotic manipulator configured to pick up the wire from between the first shuttle and the second shuttle and place the wire in a predetermined position on one or more wire routing supports in the raceway assembly tool.

15. 15. The wire assembly system of claim 14, wherein the at least one transfer robotic manipulator comprises one or more of at least one robotic arm, at least one selectively compliant articulated robotic arm, and at least one collaborative robot.

16. 15. The wire assembly system of claim 14, wherein the at least one transfer robot manipulator comprises a plurality of transfer robot manipulators spaced vertically along the top surface of the tool support structure, the plurality of transfer robot manipulators being spaced apart at least one of about 1 foot to about 2 feet, about 2 feet to about 3 feet, and about 3 feet to about 4 feet.

17. The at least one robotic manipulator at least one insertion robot manipulator disposed on the upper surface of the tool support structure, the at least one insertion robot manipulator configured to pick up the first terminal end of the wire from the first shuttle and insert the first terminal end into a predetermined originating electrical connector at a first predetermined location of the raceway assembly tool; 13. The wire assembly system of claim 12, wherein the at least one insertion robotic manipulator comprises one or more of at least one robotic arm, at least one six-axis robotic arm, at least one seven-axis robotic arm, and at least one collaborative robot.

18. 18. The wire assembly system of claim 17, wherein the at least one insertion robot manipulator is configured to pick up the second terminal end of the wire from the second shuttle and insert the second terminal end into a predetermined terminal electrical connector at a second predetermined location of the raceway assembly tool.

19. the at least one robotic manipulator includes a first insertion robotic manipulator and a second insertion robotic manipulator; the first insertion robot manipulator is mounted to a first robot transport unit disposed on the upper surface of the tool support structure, the first robot transport unit configured to translate the first insertion robot manipulator along the length of the raceway assembly tool; the first insertion robot manipulator is configured to cooperate with the first robot transport unit to pick up the first terminal end of the wire from the first shuttle and insert the first terminal end into a predetermined originating electrical connector at a first predetermined position of the raceway assembly tool; the second insertion robot manipulator is mounted to a second robot transport unit positioned on the top surface adjacent to the first robot transport unit, the second robot transport unit configured to translate the second insertion robot manipulator along the length of the raceway assembly tool; 13. The wire assembly system of claim 12, wherein the second insertion robot manipulator is configured to, in conjunction with the second robot transport unit, pick up the second terminal end of the wire from the second shuttle and insert the second terminal end into a predetermined terminal electrical connector at a second predetermined position of the raceway assembly tool.

20. The wire shuttle subsystem further comprises: a longitudinal groove disposed on the upper surface of the tool support structure and extending along the raceway assembly tool; a first transport assembly mechanically connected to the first shuttle and configured to position the first shuttle along a first longitudinal rail of the longitudinal channel; a second transport assembly mechanically connected to the second shuttle for positioning the second shuttle along a second longitudinal rail of the longitudinal channel; an unwind assembly disposed on the upper surface of the tool support structure and configured to hold the coil of wire, a first end of the wire, and a second end of the wire; an image sensor disposed adjacent the unwind assembly and configured to selectively capture images of the first end and the second end and images indicative of the state of the coil at the unwind assembly; A wire carrier identification detector provided near a wire carrier in a wire transport system, comprising: the wire carrier is configured to transport the wire from a wire preparation system to the wire assembly system; a wire carrier identification detector configured to selectively obtain an identification number from a wire carrier identification element on the wire carrier; a wire carrier identification detector in functional communication with the first transport assembly, the second transport assembly, the unwind assembly, the image sensor, the wire carrier identification detector, and the system controller; a control assembly that controls movement of the first terminal end from the unwind assembly to the first shuttle, movement of the first shuttle along the first longitudinal rail, unwinding of the coil from the unwind assembly, placement of the second terminal end from the unwind assembly onto the second shuttle, and movement of the second shuttle along the second longitudinal rail.

21. the first transport assembly includes 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; 21. The wire assembly system of claim 20, wherein the second transport assembly includes 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.

22. the image sensor comprises at least one of a digital camera, a charge-coupled device, an active pixel device, an optical scanner, and a laser scanner; 21. The wire assembly system of claim 20, wherein the wire carrier identification detector 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.

23. The unwind assembly includes: a rotating plate configured to temporarily hold the coil of wire and to unwind the wire under tension at the first end portion in response to movement of the first shuttle along the first longitudinal rail of the wire shuttle subsystem; a first end holder disposed adjacent the rotating plate and configured to temporarily hold the first terminal end of the wire; a second end holder attached to the rotating plate and configured to hold the second terminal end of the wire.

24. 24. The wire assembly system of claim 23, wherein the first end holder comprises the first shuttle when positioned on the first longitudinal rail of the longitudinal groove provided adjacent the rotating plate.

25. a work robot manipulator mounted on a support platform adjacent a proximal end region of the tool support structure; the work robot manipulator is configured to pick up the coil, the first terminal end, and the second terminal end of the wire from a wire carrier in a wire transport system, place the coil on the rotating plate of the unwind assembly, place the first terminal end on the first end holder, and place the second terminal end on the second end holder; 24. The wire assembly system of claim 23, wherein the work robotic manipulator comprises at least one of a robotic arm, a six-axis robotic arm, a collaborative robot, an electromechanical manipulator, an automated mechanical manipulator, a semi-automated mechanical manipulator, a work robot with fixed actuators, and a semi-manual robot.

26. the system controller and the work robot manipulator are configured to pick up the first terminal end of the wire from the first end holder and place the first terminal end on the first shuttle; 26. The wire assembly system of claim 25, wherein the system controller and the work robot manipulator are configured to pick up the second terminal end of the wire from the second end holder and place the second terminal end on the second shuttle when the system controller detects that the wire has been unwound from the rotating plate.

27. 1. A method for assembling an electrical raceway module, comprising: receiving raceway assembly tools at a work support structure from a raceway preparation area, wherein the work support structure is positioned alongside the tool support structure; receiving a wire from a wire preparation system for placement in the raceway assembly tool, the wire including a first end and a second end; positioning the wire on an upper surface of the tool support structure between a first shuttle holding the first end and a second shuttle holding the second end; picking up the wire having the first end and the second end from the top surface of the tool support structure, the first shuttle, and the second shuttle; placing the wire in a predetermined position in the raceway assembly tool.

28. 1. A method for assembling an electrical raceway module, comprising: receiving raceway assembly tools at a work support structure from a raceway preparation area, wherein the work support structure is positioned alongside the tool support structure; receiving a wire from a wire preparation system for placement in the raceway assembly tool, the wire including a first end and a second end; positioning the wire on an upper surface of the tool support structure between a first shuttle holding the first end and a second shuttle holding the second end; picking up the wire having the first end and the second end from the top surface of the tool support structure, the first shuttle, and the second shuttle; placing the wires in place in the raceway assembly tool; repeating the receiving, positioning, picking up, and placing of the wire for the next wire until all wires designated for autonomous placement in the raceway assembly tool have been placed; transporting the raceway assembly tool to a post-wire assembly area to prepare the electrical raceway module for attachment to an end product, and performing manual assembly operations in the raceway assembly tool.

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