Automatic electrical wiring system and method

Abstract

This invention provides an automated electrical wiring system that potentially improves the production and manufacture of electrical cabinets. [Solution] The present invention relates to a system for automating wire routing to a connector, comprising a routing arm module equipped with a routing end effector for holding and manipulating the wire end, sensors for measuring axial and radial forces as properties related to wire holding and manipulation, and a circuit that performs routing operations in response to commands and adjusts the operation of the arm and end effector considering the detected forces. The circuit further determines correct insertion and locking by inserting the wire end into the connector and detecting and evaluating the pull-out resistance with the sensors.

Description

Technical Field

[0001] Related Applications This application claims the benefit of priority of U.S. Provisional Patent Application No. 63 / 122,030, filed on December 7, 2020, U.S. Provisional Patent Application No. 63 / 164,645, filed on March 23, 2021, and U.S. Provisional Patent Application No. 63 / 164,660, filed on March 23, 2021, the contents of which are hereby incorporated by reference in their entirety.

[0002] This application is also related to the co-pending PCT patent application (Attorney Docket No. 90346) titled "SYSTEMS AND METHODS FOR AUTOMATIC ELECTRICAL WIRING WITH ENDEFFECTOR", the contents of which are hereby incorporated by reference in their entirety.

Background Art

[0003] In some embodiments, the present invention relates to an automatic electrical wiring system and method, and more particularly, but not limited to, an automatic electrical wiring system and method for electrical cabinets.

[0004] The preparation and wiring of electrical cabinets involve complex wire architecture design and difficult wiring operations. The present invention discloses an automatic electrical wiring system and method that potentially improves the production and manufacturing of electrical cabinets.

Summary of the Invention

[0005] The following is a non-exclusive list including some examples of embodiments of the present invention. The present invention also includes embodiments that include fewer features than all of an example, and embodiments that use features from multiple examples, even if not explicitly listed below.

[0006] Example 1.a. At least one wiring arm module having a wiring end effector at its distal end for holding and manipulating wires b. At least one sensor located within the wiring end effector, c. Circuit, i. By using the at least one wiring arm module equipped with the wiring end effector, a command is received to perform electrical wiring activity, ii. The circuit, which adjusts the operation of the at least one wiring arm module and the wiring end effector, taking into account the sensed properties with respect to the wire caused by the activity, An automated electrical wiring system, including...

[0007] Example 2. The automatic electrical wiring system according to Example 1, wherein the at least one parameter is one or more of the following: the state of the wire, the deformation of the wire, the position of the wire, the force applied to the wire, the torque applied to the wire, and the type of connector in the object.

[0008] Example 3. The automatic electrical wiring system according to Example 1, wherein the wiring end effector includes a wire holding element.

[0009] Example 4. The automatic electrical wiring system according to Example 1, wherein the wire holding element comprises a wire clamping element including two extensions.

[0010] Example 5. The automatic electrical wiring system according to Example 4, wherein the two extensions are two elongated extensions.

[0011] Example 6. The automatic electrical wiring system according to Example 4, wherein the two extensions are connected by an electrical mechanism.

[0012] Example 7. The automatic electrical wiring system according to Example 4, wherein the two extensions are connected by a pneumatic mechanism.

[0013] Example 8. The automated electrical wiring system according to Example 1, wherein the operation includes inserting the wires into the connectors of an object that requires electrical wiring.

[0014] Example 9. The automatic electrical wiring system according to Example 8, wherein the wire includes a motor for movement along the socket axis of the connector within the object.

[0015] Example 10. The automatic electrical wiring system according to Example 1, wherein the wire holding element includes one or more sensors for monitoring the force applied by the wire clamping element.

[0016] Example 11. The automated electrical wiring system according to Example 1, wherein the wiring end effector includes one or more sensors for monitoring the force applied to the wire retaining element.

[0017] Example 12. The automated electrical wiring system according to Example 1, wherein the wiring end effector includes a wire locking element.

[0018] Example 13. The automated electrical wiring system according to Example 1, wherein the wire locking element includes one or more motors for moving the wire locking element in one or more directions to interact with a locking mechanism in the connector.

[0019] Example 14. The automatic electrical wiring system according to Example 1, wherein the wire locking element includes one or more torque sensors for monitoring the operation of the lock of the wire locking element on the locking mechanism in the connector.

[0020] Example 15. The automatic electrical wiring system according to Example 14, wherein the wire locking element is configured to activate the locking mechanism in the connector according to a predetermined torque parameter monitored by one or more torque sensors.

[0021] Example 16. The circuit is the automatic electrical wiring system according to Example 1, which receives the command for executing the activity of the electrical wiring from at least one design console.

[0022] Example 17. The at least one design console is one or more of an electronic device, a computer, a tablet, a mobile phone, and a server, and is the automatic electrical wiring system according to Example 16.

[0023] Example 18. The at least one design console includes dedicated software for creating an electrical circuit design diagram, and is the automatic electrical wiring system according to Example 16.

[0024] Example 19. The at least one design console communicates with at least one server, and is the automatic electrical wiring system according to Example 16.

[0025] Example 20. The at least one design console includes dedicated software for creating mechanical drawings, and is the automatic electrical wiring system according to Example 16.

[0026] Example 21. The at least one design console includes dedicated software for generating a merge of an electrical circuit design diagram and mechanical drawings, and is the automatic electrical wiring system according to Example 16.

[0027] Example 22. The at least one design console includes dedicated software for generating a wire routing sequence according to one or more of an electrical circuit design diagram and mechanical drawings, and is the automatic electrical wiring system according to Example 16.

[0028] Example 23. The automatic electrical wiring system according to Example 1 further includes a monitoring system.

[0029] Example 24. The monitoring system includes one or more cameras, and is the automatic electrical wiring system according to Example 23.

[0030] Example 25. The monitoring system is the automatic electrical wiring system according to Example 23, wherein the monitoring system includes one or more sensors.

[0031] Example 26. The monitoring system is the automatic electrical wiring system according to Example 23, wherein the monitoring system includes one or more force sensors.

[0032] Example 27. The monitoring system is the automatic electrical wiring system according to Example 23, wherein the monitoring system includes one or more torque sensors.

[0033] Example 28. The monitoring system is the automatic electrical wiring system according to Example 23, wherein the monitoring system includes one or more current sensors.

[0034] Example 29. The automatic electrical wiring system according to Example 1, wherein the at least one wiring arm module includes a plurality of joints.

[0035] Example 30. The automatic electrical wiring system according to Example 1, wherein at least one wiring arm module is mounted on a rail.

[0036] Example 31. The automated electrical wiring system according to Example 1, wherein at least one wiring arm module is configured to approach the object requiring electrical wiring from the side.

[0037] Example 32. The automated electrical wiring system according to Example 1, wherein at least one wiring arm module is configured to approach the object requiring electrical wiring from above.

[0038] Example 33. The automated electrical wiring system according to Example 1, wherein at least one wiring arm module is configured to approach the object requiring electrical wiring along the terminal wire port angle.

[0039] Example 34. The automated electrical wiring system according to Example 1, wherein two wiring arm modules cooperate with each other during the operation of the wire.

[0040] Example 35. The automated electrical wiring system according to Example 34, wherein the two wiring arm modules during the operation are separated from each other to apply tension to the wire.

[0041] Example 36. The automatic electrical wiring system according to Example 35, wherein no tension is applied to the portion of the wire that is not held between the two wiring arm modules.

[0042] Example 37. The automated electrical wiring system according to Example 34, wherein during the operation, one of the two wiring arm modules grips the wire and the other wiring arm module slides along the wire to a desired position.

[0043] Example 38. The automatic electrical wiring system according to Example 35, wherein the wire held without tension is approximately 1% to approximately 50% of the total length of the wire.

[0044] Example 39. The automated electrical wiring system according to Example 34, wherein the system is configured to monitor the movement of each of the two wiring arm modules.

[0045] Example 40. The automated electrical wiring system according to Example 39, wherein the motion is one or more of the motion of the other relative to one of the two wiring arm modules, the motion of each of the two wiring arm modules relative to the connector, the motion of each of the two wiring arm modules relative to the object, the distance between the two wiring arm modules, and the tension of the wire held between the two wiring arm modules.

[0046] Example 41. The automatic electrical wiring system according to Example 40, wherein the system is configured to correct the motion when a predetermined value is sensed with respect to the motion.

[0047] Example 42. The automated electrical wiring system according to Example 1, further comprising a wire preparation module configured to prepare wires for insertion into objects requiring electrical wiring.

[0048] Example 43. The automated electrical wiring system according to Example 42, wherein the wire preparation module provides the wires ready for use to the at least one wiring arm module.

[0049] Example 44. The automatic electrical wiring system according to Example 1, further comprising the object requiring electrical wiring.

[0050] Example 45. The automatic electrical wiring system according to Example 40, wherein the object is an electrical cabinet.

[0051] Example 46. The automated electrical wiring system according to Example 42, wherein the electrical cabinet includes one or more smart components configured to assist the electrical wiring.

[0052] Example 47. The automated electrical wiring system according to Example 43, wherein the one or more smart components are one or more of a smart wire, a smart duct, a latch, a holder, and a marker.

[0053] Example 48. A method for automatically connecting at least one wire to at least one connector in a component, a. Automatically gripping the distal end of at least one wire with at least one wire holder, b. Automatically move the at least one wire holder so that the distal end of the at least one wire is brought closer to the at least one connector. c. Automatically inserting the distal end of the at least one wire into the at least one connector. d. Automatically evaluate whether the at least one wire is properly connected to the at least one connector. Includes, The method further comprises sensing at least one parameter of the at least one wire relating to the at least one connector during the automatic plugging and automatic evaluation.

[0054] Example 49. The method according to Example 55, wherein the at least one parameter is one or more of the following: the state of the at least one wire, the deformation of the at least one wire, the position of the at least one wire, the force applied to the at least one wire, and the torque applied to the at least one wire.

[0055] Example 50. The method according to Example 55, wherein the insertion is performed by moving the at least one wire holder.

[0056] Example 51. The method according to Example 55, wherein the at least one wire is a harness wire including multiple distal ends.

[0057] Example 52. The method according to Example 55, wherein the insertion is performed by moving the robot arm to which the at least one wire holder is attached.

[0058] Example 53. The method of Example 55, wherein the sensing includes sensing a force applied to the at least one wire when it comes into contact with the at least one connector in the component.

[0059] Example 54. The method according to Example 55, further comprising activating at least one locking mechanism to automatically lock the at least one wire in the at least one connector.

[0060] Example 55. The method of Example 55, wherein the automatic evaluation includes pulling back the at least one wire from the at least one connector.

[0061] Example 56. The method of Example 62, wherein the evaluation includes sensing whether the at least one wire resists being pulled back.

[0062] Example 57. The method according to Example 55, wherein two wiring arm modules cooperate with each other when making the connection of at least one wire.

[0063] Example 58. The method according to Example 57, wherein the two wiring arm modules being connected are spaced apart from each other to exert tension on at least one wire.

[0064] Example 59. The method of Example 58, wherein no tension is applied to the portion of the wire that is not held between the two wiring arm modules.

[0065] Example 60. The method according to Example 58, wherein one of the two wiring arm modules being connected grips the wire and the other wiring arm module slides along the wire to a desired position.

[0066] Example 61. The method according to Example 59, wherein the wire held without tension is approximately 1% to approximately 50% of the total length of the wire.

[0067] Example 62. The method of Example 57, further comprising monitoring the movement of each of the two wiring arm modules.

[0068] Example 63. The method of Example 57, wherein the motion is one or more of the motion of the other relative to one of the two wiring arm modules, the motion of each of the two wiring arm modules relative to the connector, the motion of each of the two wiring arm modules relative to the object, the distance between the two wiring arm modules, and the tension of the wire held between the two wiring arm modules.

[0069] Example 64. The wiring method according to Example 63, further comprising correcting the motion when a predetermined value is sensed with respect to the motion.

[0070] Example 65.a. Wire delivery unit, b. At least one wiring arm module having a wiring end effector at its distal end for manipulating a wire received by the wire delivery unit so as to be inserted into a connector in an object requiring electrical wiring, c. A circuit that adjusts the operation of the wire delivery unit and the at least one wiring arm module using at least one parameter related to the need for the electrical wiring, An automated electrical wiring system, including...

[0071] Example 66. The automated electrical wiring system according to Example 65, wherein the wire delivery unit is a wire preparation module for preparing the wire to be inserted into the connector in the object requiring electrical wiring.

[0072] Example 67. The automated electrical wiring system according to Example 65, wherein the wire delivery unit includes a pre-fabricated wire that is inserted into the connector in the object requiring the electrical wiring.

[0073] Example 68.a. A wire holding element having two extensions, b. At least one sensor configured to monitor the force applied to at least one wire held by the wire holding element, Wiring end effectors, including...

[0074] Example 69. The wiring end effector according to Example 68, wherein the two extensions are two elongated extensions.

[0075] Example 70. The wiring end effector according to Example 68, wherein at least one sensor is located within the wire holding element.

[0076] Example 71. The wiring end effector according to Example 68, wherein at least one sensor is located within the two extensions.

[0077] Example 72. The wiring end effector according to Example 68, further comprising a wire locking element including a connector locking mechanism actuator.

[0078] Example 73. A method for automatically wiring an object that requires electrical wiring, a. To receive an electrical wiring design drawing of the object requiring the electrical wiring, and a wire routing sequence according to the design drawing. b. Prepare multiple wires. c. Delivering the prepared wire to the automatic wiring arm module. d. Automatically routing the prepared wires into the object requiring electrical wiring according to the routing sequence of the generated wires, The method, including the method described above.

[0079] Example 74. A method for automatically wiring an object that requires electrical wiring, a. To draw a design drawing of the electrical wiring of the object that requires the aforementioned electrical wiring. b. Automatically generate a wire routing sequence according to the aforementioned design drawing. c. Prepare multiple wires. d. Delivering the prepared wire to the automatic wiring arm module. e. Automatically routing the prepared wires into the object requiring electrical wiring according to the routing sequence of the generated wires, The method, including the method described above.

[0080] Example 75.a. At least one wiring arm module having a wiring end effector at its distal end for manipulating a wire so that it is inserted into a hole in a connector within the component, b. A circuit that adjusts the operation of the at least one wiring arm module and the wiring end effector using at least one parameter related to the connector, c. One or more sensors configured to detect parameters related to the wire while inserted into the hole of the connector by the wiring end effector, An automated electrical wiring system, including...

[0081] Example 76.a. A wire holding element having two extensions, b. A locking device equipped with an electrical terminal connector locking mechanism actuator, Wiring end effectors, including...

[0082] Example 77. The wiring end effector according to Example 76, further comprising at least one sensor configured to monitor a force applied to at least one wire held by the wire holding element.

[0083] Example 78.a. Wire holding element having two extensions, b. A locking device equipped with an electrical terminal connector locking mechanism actuator. c. A wire feeder configured to feed at least one wire to the wire holding element, Wiring end effectors, including...

[0084] Example 79. The wiring end effector according to Example 78, further comprising at least one sensor configured to monitor a force applied to at least one wire held by the wire holding element.

[0085] Example 80.a. A wire holding element having two extensions, b. A camera configured to monitor the operation of the wire holding element, Wiring end effectors, including...

[0086] Example 81. The wiring end effector according to Example 80, further comprising a locking device including a connector locking mechanism actuator.

[0087] Example 82. The wiring end effector according to Example 80, further comprising a wire feeder configured to feed at least one wire to the wire holding element.

[0088] Example 83. The wiring end effector according to Example 80, further comprising at least one sensor configured to monitor the force applied to at least one wire held by the wire retaining element.

[0089] Example 84.a. A wire holding element having two extensions, b. A wire cutter configured to cut the distal portion of a wire held by the wire holding element, Wiring end effectors, including...

[0090] Example 85. The wiring end effector according to Example 84, further comprising a camera configured to monitor the operation of the wire retaining element.

[0091] Example 86. The wiring end effector according to Example 84, further comprising a locking device including a connector locking mechanism actuator.

[0092] Example 87. The wiring end effector according to Example 84, further comprising a wire feeder configured to feed at least one wire to the wire holding element.

[0093] Example 88. The wiring end effector according to Example 84, further comprising at least one sensor configured to monitor a force applied to at least one wire held by the wire holding element.

[0094] Example 89. A method for drawing a design for automatic wiring of at least one object requiring electrical wiring within an automatic electrical wiring system design console, a. Receiving rules regarding electrical circuit diagrams and / or mechanical drawings from at least one user. b. Receiving the electrical circuit diagram and / or the mechanical drawing on the design console, c. Perform an automated check of the design in accordance with the aforementioned rules. d. To generate the original wiring design by merging the electrical circuit diagram with the mechanical drawing. e. Prepare the robot wiring diagram. The method, including the method described above.

[0095] Example 90. The method according to Example 89, wherein the rule is a rule relating to one or more standards, special requirements by a client, technical limitations, and personal rules inserted by the one or more users.

[0096] Example 91. The method according to Example 89, wherein different designs are provided by different users and inserted independently into the design console.

[0097] Example 92. The method according to Example 89, wherein the design is created elsewhere and manually inserted into the design console.

[0098] Example 93. The method according to Example 89, further comprising automatically approving the design after the execution.

[0099] Example 94. The method of Example 89, further comprising performing a second check on the original wiring design in accordance with the rules.

[0100] Example 95. The method according to Example 89, wherein the robot wiring design diagram includes one or more of the following: the length and number of ducts, components to be inserted into the object, a series of routing paths for one or more wires, and a sequence for arranging one or more wires on the routing paths.

[0101] Example 96. The method according to Example 89, further comprising wiring to the at least one object according to the robot wiring design drawing.

[0102] Example 97. The method of Example 89, further comprising running a simulation of the robot wiring diagram before wiring the at least one object according to the robot wiring diagram.

[0103] Example 98. A method for arranging a wire along a path using two robot arms, a. The first end of the wire is held by the first robot arm. b. Positioning the first end of the wire at the first position along the path, c. By sliding the second robot arm along the wire toward the first position, the wire is positioned along the path. The method, including the method described above.

[0104] Example 99. A method for automatically wiring a light-emitting unit by connecting at least one wire to at least one connector, a. The wire holder automatically grasps the distal end of the wire. b. Automatically move the wire holder so that the distal end of the wire is brought closer to the connector. c. Automatically inserting the distal end of the wire into the connector. d. Automatically evaluate whether the at least one wire is properly connected to the at least one connector. Includes, The method further comprises sensing at least one parameter of the wires relating to the connector during the automatic insertion and automatic evaluation.

[0105] Example 100. The method according to Example 99, wherein the at least one parameter is one or more of the following: the state of the wire, the deformation of the wire, the position of the wire, the force applied to the wire, and the torque applied to the wire.

[0106] Example 101. The method according to Example 99, wherein the insertion is performed by moving the wire holder.

[0107] Example 102. The method according to Example 99, wherein the insertion is performed by moving the connector.

[0108] Example 103. The method according to Example 99, wherein the insertion is performed by moving the robot arm to which the wire holder is attached.

[0109] Example 104. The method according to Example 99, wherein the sensing includes sensing a force applied to the at least one wire as it comes into contact with the at least one connector.

[0110] Example 105. The method according to Example 99, further comprising automatically locking the at least one wire in the at least one connector by activating at least one locking mechanism.

[0111] Example 106. The method according to Example 99, wherein the automatic evaluation includes pulling back the at least one wire from the at least one connector.

[0112] Example 107. The method according to Example 106, wherein the evaluation includes sensing whether the at least one wire resists being pulled back.

[0113] The following is a further non-exclusive list containing some examples of embodiments of the present invention. The present invention also includes embodiments containing fewer features than all of the examples, and embodiments using features from multiple examples, even if not expressly enumerated below.

[0114] Example 1001.a. At least one wiring arm module having a wiring end effector at its distal end for manipulating a wire so that it is inserted into an object requiring electrical wiring, b. A circuit that adjusts the operation of the wire preparation module and the at least one wiring arm module using at least one parameter related to the need for the electrical wiring, An automated electrical wiring system, including...

[0115] Example 1002. The automated electrical wiring system according to Example 1001, further comprising a wire preparation module.

[0116] Example 1003. The automated electrical wiring system according to Example 1001 or Example 1002, wherein the wiring preparation module is configured to prepare wires for insertion into objects requiring electrical wiring.

[0117] Example 1004. The wire preparation module is an automated electrical wiring system according to any one of Examples 1001 to 1003, comprising a plurality of wire stocks.

[0118] Example 1005. The automatic electrical wiring system according to any one of Examples 1001 to 1004, wherein the wire preparation module includes one or more wire manipulators.

[0119] Example 1006. An automated electrical wiring system according to any one of Examples 1001 to 1005, wherein one or more wire manipulators are mounted on rails for movement between components of the wire preparation module.

[0120] Example 1007. An automated electrical wiring system according to any one of Examples 100100 to 6, wherein the wire preparation module includes at least one wire stripper module.

[0121] Example 1008. An automated electrical wiring system according to any one of Examples 1001 to 1007, wherein the wire preparation module includes a plurality of wire end connector mounting modules.

[0122] Example 1009. An automated electrical wiring system according to any one of Examples 1001 to 1008, wherein the wire preparation module includes a wire cutter.

[0123] Example 1010. An automated electrical wiring system according to any one of Examples 1001 to 1009, wherein the wire preparation module includes a labeling module.

[0124] Example 1011. The automatic electrical wiring system according to any one of Examples 1001 to 1010, wherein the at least one wiring arm module includes a plurality of joints.

[0125] Example 1012. The automatic electrical wiring system according to any one of Examples 1001 to 1011, wherein at least one wiring arm module is mounted on a rail.

[0126] Example 1013. An automated electrical wiring system according to any one of Examples 1001 to 1012, wherein at least one wiring arm module is configured to approach the object requiring electrical wiring from the side.

[0127] Example 1014. An automated electrical wiring system according to any one of Examples 1001 to 1013, wherein at least one wiring arm module is configured to approach the object requiring electrical wiring from above.

[0128] Example 1015. An automated electrical wiring system according to any one of Examples 1001 to 1014, wherein the wiring end effector includes a wire holding element.

[0129] Example 1016. An automatic electrical wiring system according to any one of Examples 1001 to 1015, wherein the wire holding element comprises a wire clamping element having two elongated extensions.

[0130] Example 1017. An automatic electrical wiring system according to any one of Examples 1001 to 1016, wherein the two elongated extensions are connected by an electrical mechanism.

[0131] Example 1018. An automatic electrical wiring system according to any one of Examples 1001 to 1017, wherein the wire holding element includes a motor for the horizontal movement of the wire holding element.

[0132] Example 1019. An automated electrical wiring system according to any one of Examples 1 to 18, wherein the wire holding element includes one or more sensors for monitoring the force applied by the wire clamping element.

[0133] Example 1020. An automated electrical wiring system according to any one of Examples 1001 to 1019, wherein the wiring end effector includes a wire locking element.

[0134] Example 1021. An automatic electrical wiring system according to any one of Examples 1001 to 1020, wherein the wire locking element includes a terminal block actuator.

[0135] Example 1022. An automated electrical wiring system according to any one of Examples 1001 to 1021, wherein the wire locking element includes a motor for moving the actuator vertically to interact with a terminal block.

[0136] Example 1023. An automated electrical wiring system according to any one of Examples 1001 to 1022, wherein the wire preparation module provides the wires ready for use to the at least one wiring arm module.

[0137] Example 1024. The wire preparation module provides a ready-to-use multi-end harness wire in the automated electrical wiring system according to any one of Examples 1001 to 1023.

[0138] Example 1025. An automated electrical wiring system according to any one of Examples 1001 to 1024, wherein the circuit receives the at least one parameter related to the need for the electrical wiring from at least one design console.

[0139] Example 1026. An automated electrical wiring system according to any one of Examples 1001 to 1025, wherein the at least one design console is one or more of electronic devices, computers, tablets, mobile phones, and servers.

[0140] Example 1027. An automated electrical wiring system according to any one of Examples 1001 to 1026, wherein the at least one design console communicates with at least one server.

[0141] Example 1028. An automated electrical wiring system according to any one of Examples 1001 to 1027, wherein the at least one design console includes dedicated software for creating electrical circuit design diagrams.

[0142] Example 1029. An automated electrical wiring system according to any one of Examples 1001 to 1028, wherein the at least one design console includes dedicated software for creating mechanical drawings.

[0143] Example 1030. An automated electrical wiring system according to any one of Examples 1001 to 1029, wherein the at least one design console includes dedicated software for generating a merge of electrical circuit design drawings and mechanical drawings.

[0144] Example 1031. An automated electrical wiring system according to any one of Examples 1001 to 1030, wherein the at least one design console includes dedicated software for creating a bill of materials.

[0145] Example 1032. An automated electrical wiring system according to any one of Examples 1001 to 1031, wherein the at least one design console includes dedicated software for generating a wire routing sequence according to one or more of the electrical circuit design drawings and the mechanical drawings.

[0146] Example 1033. An automated electrical wiring system according to any one of Examples 1001 to 1032, further comprising a monitoring system.

[0147] Example 1034. The monitoring system is an automated electrical wiring system according to any one of Examples 1001 to 1033, comprising one or more cameras.

[0148] Example 1035. The monitoring system is an automated electrical wiring system according to any one of Examples 1001 to 1034, comprising one or more sensors.

[0149] Example 1036. The monitoring system is an automated electrical wiring system according to any one of Examples 1001 to 1035, comprising one or more force sensors.

[0150] Example 1037. The monitoring system is an automatic electrical wiring system according to any one of Examples 1001 to 1036, comprising one or more torque sensors.

[0151] Example 1038. The monitoring system is an automated electrical wiring system according to any one of Examples 1001 to 1037, comprising one or more current sensors.

[0152] Example 1039. An automated electrical wiring system according to any one of Examples 1001 to 1038, further comprising the object requiring electrical wiring.

[0153] Example 1040.a. Wire delivery unit, b. At least one wiring arm module having a wiring end effector at its distal end for manipulating a wire so that it is inserted into an object requiring electrical wiring, c. A circuit that adjusts the operation of the wire preparation module and the at least one wiring arm module using at least one parameter related to the need for the electrical wiring, An automated electrical wiring system, including...

[0154] Example 1041. The automated electrical wiring system according to Example 1040, wherein the wire delivery unit is a wire preparation module for preparing the wire to be inserted into an object requiring electrical wiring.

[0155] Example 1042. The automated electrical wiring system according to Example 1040, wherein the wire delivery unit includes a pre-fabricated wire that is inserted into the object requiring the electrical wiring.

[0156] Example 1043.a. A wire holding element having two elongated extensions, b. A wire locking element equipped with a terminal block actuator, Wiring end effectors, including...

[0157] Example 1044. A method for preparing electrical wires by an automated wire preparation machine comprising a plurality of wire stocks, one or more wire manipulators, at least one wire stripper module, a plurality of wire end connector mounting modules, at least one labeling module, and a wire cutter, a. The first wire manipulator from one or more wire manipulators grasps the first end of a wire from the plurality of wire stocks. b. By moving the first end of the wire into the at least one stripper module, the coating on the first end of the wire is stripped, exposing the wire core. c. Release the length of the wire as needed for the length of the prepared wire. d. The wire is grasped at the position of the required length as described above by a second wire manipulator from one or more wire manipulators. e. To generate the second end of the wire by moving the wire into the wire cutter. f. By moving the second end of the wire into the at least one stripper module, the coating on the second end of the wire is stripped, exposing the wire core. The method, including the method described above.

[0158] Example 1045. The method according to Example 1044, further comprising attaching a wire end connector to the stripped first end of the wire by moving the stripped first end of the wire into one of the plurality of wire end connector mounting modules.

[0159] Example 1046. The method according to Example 1044 or Example 1045, further comprising attaching a wire end connector to the stripped second end of the wire by moving the stripped second end of the wire into one of the plurality of wire end connector mounting modules.

[0160] Example 1047. The method according to any one of Examples 1044 to 1046, further comprising moving the first end of the wire into the labeling module for labeling the wire.

[0161] Example 1048. The method according to any one of Examples 1044 to 1047, further comprising moving the second end of the wire into the labeling module for labeling the wire.

[0162] Example 1049. A method for automatically wiring an object that requires electrical wiring, a. To receive an electrical wiring design drawing of the object requiring the electrical wiring, and a wire routing sequence according to the design drawing. b. Prepare multiple wires. c. Delivering the prepared wire to the automatic wiring arm module. d. Automatically routing the prepared wires into the object requiring electrical wiring according to the routing sequence of the generated wires, The method, including the method described above.

[0163] Example 1050. A method for automatically wiring an object that requires electrical wiring, a. To draw a design drawing of the electrical wiring of the object that requires the aforementioned electrical wiring. b. Automatically generate a wire routing sequence according to the aforementioned design drawing. c. Prepare multiple wires. d. Delivering the prepared wire to the automatic wiring arm module. e. Automatically routing the prepared wires into the object requiring electrical wiring according to the routing sequence of the generated wires, The method, including the method described above.

[0164] Unless otherwise defined, all technical and / or scientific terms used herein have the same meaning as those commonly understood by those skilled in the art to which the present invention pertains. Similar or equivalent methods and materials may be used in carrying out or testing the present invention, but exemplary methods and / or materials are described below. In case of any conflict, the patent specification, including definitions, shall prevail. Furthermore, the materials, methods, and examples are merely examples and are not necessarily intended to be limiting.

[0165] As those skilled in the art will understand, some embodiments of the present invention may be embodied as systems, methods, or computer program products. Accordingly, some embodiments of the present invention may take the form of entirely hardware embodiments, entirely software embodiments (including firmware, resident software, microcode, etc.), or embodiments combining software and hardware aspects, which may be commonly referred herein as “circuits,” “modules,” or “systems.” Furthermore, some embodiments of the present invention may take the form of computer program products embodied in one or more computer-readable media in which computer-readable program code is embodied. Implementation of some embodiments of the present invention methods and / or systems may involve performing and / or carrying out selected tasks manually, automatically, or in combination thereof. Furthermore, according to the actual instrumentation and installation of some embodiments of the methods and / or systems of the present invention, some selected tasks may be carried out by hardware, software, or firmware, and / or in combination thereof, for example, using an operating system.

[0166] For example, hardware for performing selected tasks according to some embodiments of the present invention may be implemented as a chip or circuit. As software, selected tasks according to some embodiments of the present invention may be implemented as a set of software instructions executed by a computer using any suitable operating system. In exemplary embodiments of the present invention, one or more tasks according to some exemplary embodiments of the method and / or system described herein are performed by a data processor, such as a computing platform for executing a set of instructions. Optionally, the data processor includes volatile memory for storing instructions and / or data, and / or non-volatile storage for storing instructions and / or data, such as a magnetic hard disk and / or removable media. Optionally, network connectivity is also provided. A display and / or user input devices such as a keyboard or mouse are also optionally provided.

[0167] Some embodiments of the present invention may utilize any combination of one or more computer-readable media. A computer-readable media may be a computer-readable signal medium or a computer-readable storage medium. A computer-readable storage medium may, for example, be an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any preferred combination thereof. More specific examples of computer-readable storage media include electrical connections having one or more communication lines, portable computer diskettes, hard disks, random access memory (RAM), read-only memory (ROM), electrically erasable PROM (EEPROM or flash memory), optical fibers, compact disk read-only memory (CD-ROM), optical storage devices, magnetic storage devices, or any preferred combination thereof. In the context of this document, a computer-readable storage medium may be any tangible medium that can contain or store programs for use by, or in connection with, an instruction execution system, apparatus, or device.

[0168] A computer-readable signal medium may include, for example, a propagating data signal in which computer-readable program code is embodied, either in the baseband or as part of a carrier wave. Such propagating signals may take any of various forms, including but not limited to electromagnetic, optical, or any combination thereof. A computer-readable signal medium may not be a computer-readable storage medium, but any computer-readable medium capable of communicating, propagating, or carrying a program for use by, or in connection with, an instruction execution system, apparatus, or device.

[0169] Program code and / or data used thereby, embodied on a computer-readable storage medium, may be transmitted using any suitable medium, including but not limited to wireless, wired, fiber optic cable, RF, or any suitable combination thereof.

[0170] Computer program code for performing operations for some embodiments of the present invention may be written in any combination of one or more programming languages, including, for example, object-oriented programming languages ​​such as Java, Smalltalk, and C++, and conventional procedural programming languages ​​such as, for example, the "C" programming language or a similar programming language. The program code can run as a standalone software package, entirely on the user's computer, partially on the user's computer, partially on the user's computer and partially on a remote computer, or entirely on a remote computer or server. In the latter scenario, the remote computer can be connected to the user's computer via any type of network, including a local area network (LAN) or a wide area network (WAN), or it can be connected to an external computer (for example, via the Internet using an Internet Service Provider).

[0171] Some embodiments of the present invention are described below with reference to flowcharts and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the present invention. It will be understood that each block in a flowchart and / or block diagram, and combinations of blocks in a flowchart and / or block diagram, can be implemented by computer program instructions. These computer program instructions can be provided to the processor of a general-purpose computer, a special-purpose computer, or other programmable data processing device to create a machine such that instructions executed via the processor of the computer or other programmable data processing device create means for performing functions / actions specified in blocks or combinations of blocks in a flowchart and / or block diagram.

[0172] Furthermore, these computer program instructions may be stored in a computer-readable medium that can instruct a computer, other programmable data processing device, or other device to function in a particular way, thereby manufacturing a product which includes instructions that perform functions / actions specified in a block or a series of block flowcharts and / or block diagrams.

[0173] Computer program instructions may be loaded onto a computer, other programmable device, or other device to create a computer implementation process, such that the instructions executed on the computer or other programmable device perform a series of operational steps, providing a process for carrying out functions / actions specified in a block or multi-block flowchart and / or block diagram.

[0174] Some of the methods described herein are generally designed for computer use only and may not be suitable or practical for human professionals to perform entirely manually. Human professionals who wish to perform similar tasks manually, such as inserting wires into sockets and / or designing the architecture of electrical cabinets, can be expected to employ entirely different methods, such as methods that leverage their expertise and / or methods that leverage the pattern recognition capabilities of the human brain, which should be far more efficient than performing the steps of the methods described herein manually.

[0175] Several embodiments of the present invention will be described herein, merely as examples, with reference to the accompanying drawings. While the drawings will be given in detail, it is emphasized that the illustrated details are for illustrative purposes only, illustrating the embodiments of the present invention. In this regard, the description with reference to the drawings will make it clear to those skilled in the art how embodiments of the present invention may be carried out. [Brief explanation of the drawing]

[0176] [Figure 1A] This is a schematic diagram illustrating an exemplary automatic wiring system according to several embodiments of the present invention. [Figure 1B] This is a flowchart illustrating an exemplary method of merging electrical circuit diagrams with mechanical drawings within and by a design console, according to some embodiments of the present invention. [Figure 2] This is a schematic diagram of an exemplary automatic wiring unit / system according to several embodiments of the present invention. [Figure 3] This is a schematic diagram illustrating an exemplary automatic wiring unit / system according to several embodiments of the present invention. [Figure 4] This is a schematic diagram of an exemplary wire preparation module according to several embodiments of the present invention. [Figure 5] Figures A and B are schematic diagrams of exemplary wire manipulators according to several embodiments of the present invention. [Figure 6A] This is a flowchart illustrating an exemplary wire preparation method according to several embodiments of the present invention. [Figure 6B] This is a flowchart illustrating an exemplary wire preparation method according to several embodiments of the present invention. [Figure 6C] This is a flowchart illustrating an exemplary wire preparation method according to several embodiments of the present invention. [Figure 7A] An exemplary wiring arm module including multiple joints according to several embodiments of the present invention. [Figure 7B1] This is a schematic diagram of an exemplary and typical action cycle performed by a human when routing wires within a connector. [Figure 7B2] This is a schematic diagram of an exemplary and typical action cycle performed by a human when routing wires within a connector. [Figure 7B3] This is a schematic diagram of an exemplary and typical action cycle performed by a human when routing wires within a connector. [Figure 7B4] This is a schematic diagram of an exemplary and typical action cycle performed by a human when routing wires within a connector. [Figure 7B5] This is a schematic diagram of an exemplary and typical action cycle performed by a human when routing wires within a connector. [Figure 8A] This is a schematic diagram of an exemplary wiring arm module according to several embodiments of the present invention. [Figure 8B] This is a schematic diagram of an exemplary wiring arm module according to several embodiments of the present invention. [Figure 9A] This is a schematic diagram of an exemplary wiring end effector module according to several embodiments of the present invention. [Figure 9B] This is a schematic diagram of a wire holding element component according to several embodiments of the present invention. [Figure 9C1] This is a schematic diagram of a sensor located on an elongated extension according to some embodiments of the present invention. [Figure 9C2]This is a schematic diagram of an exemplary gimbal block in which extensions are connected, according to some embodiments of the present invention. [Figure 9C3] This is a schematic diagram of an exemplary gimbal block in which extensions are connected, according to some embodiments of the present invention. [Figure 9D] This is a schematic diagram of an exemplary wire lock element according to several embodiments of the present invention. [Figure 9E1] This is a schematic diagram illustrating several exemplary interactions between a wiring end effector module and different types of terminal blocks, according to several embodiments of the present invention. [Figure 9E2] This is a schematic diagram of an exemplary ferrule according to several embodiments of the present invention. [Figure 9E3] This is a schematic diagram of an exemplary ferrule according to several embodiments of the present invention. [Figure 9F] This is a flowchart illustrating an exemplary wiring method using an exemplary wiring end effector module according to several embodiments of the present invention. [Figure 9G] This is a flowchart illustrating an exemplary wiring method using an exemplary wiring end effector module according to several embodiments of the present invention. [Figure 9H] This is a flowchart illustrating an exemplary wiring method using an exemplary wiring end effector module according to several embodiments of the present invention. [Figure 10] This is a flowchart illustrating an exemplary wiring method using a wiring arm module according to several embodiments of the present invention. [Figure 11] This is a schematic diagram illustrating the data flow and operation of an automated wiring system according to several embodiments of the present invention. [Figure 12] This is a schematic diagram of automatic electrical wiring for a light-emitting unit according to several embodiments of the present invention. [Figure 13] Figures A and B are schematic diagrams of wire end effectors for automatic electrical wiring of a light-emitting unit according to several embodiments of the present invention. [Figure 14]This is a schematic diagram illustrating exemplary forces used for inserting a wire into a wire terminal, according to some embodiments of the present invention. [Figure 15] This is a schematic diagram of an exemplary horizontal automatic wiring system equipped with a dedicated wire preparation module, according to some embodiments of the present invention. [Figure 16] This is a schematic diagram of another exemplary horizontal automatic wiring system with a dedicated wire preparation module, according to some embodiments of the present invention. [Figure 17A] This is a schematic diagram illustrating an exemplary horizontal automatic wiring system according to several embodiments of the present invention. [Figure 17B] This is a schematic diagram illustrating an exemplary horizontal automatic wiring system according to several embodiments of the present invention. [Figure 17C] This is a schematic diagram illustrating an exemplary horizontal automatic wiring system according to several embodiments of the present invention. [Figure 17D] This is a schematic diagram illustrating an exemplary horizontal automatic wiring system according to several embodiments of the present invention. [Figure 18] Figures A and B are schematic diagrams of a wiring process using two automated mechanical arms and a horizontal wire preparation module according to several embodiments of the present invention. [Figure 19] This graph illustrates an exemplary phase of inserting a wire into an electrical terminal connector, identified by a sensor within the gripper, according to several embodiments of the present invention. [Figure 20] A to C are three different examples of forces sensed by the gripper in three different scenarios according to several embodiments of the present invention. [Figure 21] This document presents several test experiments demonstrating the characteristics of exemplary scenarios according to several embodiments of the present invention. [Modes for carrying out the invention]

[0177] In some embodiments, the present invention relates to automatic electrical wiring systems and methods, and more particularly, but not limited to, automatic electrical wiring systems and methods for electrical cabinets.

[0178] overview One aspect of several embodiments of the present invention relates to designing the wiring for an electrical cabinet and performing the wiring using an automated machine.

[0179] In some embodiments, automated wiring operations include designing and simulating wiring sequences, which can reduce the setup time engineering for electrical cabinet wiring and shorten the actual wiring execution time. In some embodiments, automated wiring machines are equipped with multiple sensors for tactile feedback, which can increase the accuracy of wire insertion into the correct location and shorten the validation process time. In some embodiments, automated wiring systems may reduce setup time by performing multiple optimization processes using micro and macro motion analysis with artificial intelligence (AI) algorithms. In some embodiments, automated wiring systems may increase the accuracy of wire insertion into the correct location by utilizing deep learning and / or vision-based algorithms for component location and identification, which can shorten the validation process time and improve the wiring cycle / execution time for cabinets. In some embodiments, automated wiring systems utilize reinforcement learning for impedance-controlled wire insertion, and optionally also utilize search routines, all of which can improve the accuracy / performance of wire insertion into the correct location.

[0180] In some embodiments, the automatic wiring system includes instructions to enable the placement of wires within cable channels / tracks to prevent unplanned wiring within the cabinet. In some embodiments, the automatic wiring system includes instructions to prevent wire twisting during the operation of securing the proper routing of cables along a path. In some embodiments, the automatic wiring system manages cable slack when the cable is held in two places (but not necessarily at both ends). In some embodiments, the automatic wiring system includes instructions to avoid obstacles to cables along a route in a duct or to obstacles to the actual cable tray / duct. In some embodiments, the automatic wiring system includes instructions to connect the routing with a harness (i.e., connect with a multi-end (more than two) harness) with collision avoidance and slack management by optionally securing the position of slack and cable hang-downs by identifying junctions. In some embodiments, the automatic wiring system includes instructions to consider the length and / or number of wires previously positioned within cable tracks / channels for the design and / or routing and / or positioning of multiple wires within an electrical cabinet. In some embodiments, routing cables within a cable track / channel requires at least two cable manipulators (or alternatively, robotic arms, etc.), one to fix the cable's position (e.g., at a corner) and the other to continue positioning the cable within the cable track / channel.

[0181] One aspect of several embodiments of the present invention relates to the insertion of a wire into an electrical connector by a robotic manipulator. In some embodiments, the robotic manipulator comprises a smart holder including a plurality of sensors. In some embodiments, the holder includes a finger-shaped holder. In some embodiments, the insertion of the wire comprises manipulating the wire and receiving feedback from the plurality of sensors regarding the state of the wire and optionally regarding the connector of the component. Hereafter, the term “connector” refers to the location on a component to which a wire and / or wirehead is connected. Hereafter, the term “component” refers to any component that is part of an object requiring wiring (e.g., an electrical cabinet) and comprises a connector to which a wire and / or wirehead can be connected, such as a circuit breaker, an electrical component, a computer component, an electronic component, etc. The term “wirehead” hereafter refers to any end of a wire, whether or not it includes a dedicated mounting portion (e.g., a ferrule) or a dedicated connector for only exposed metal wire (e.g., for data and / or video and / or networking, etc.).

[0182] One aspect of several embodiments of the present invention relates to the manipulation of a wire by two robotic manipulators, wherein the robotic manipulators hold the wire from two different points on the wire. In some embodiments, manipulating the wire includes maintaining a certain level of tension on the wire. In some embodiments, manipulating the wire includes identifying the three-dimensional coordinates of each of the two manipulators relative to a target while holding the wire to perform a wiring action. Before describing in detail at least one embodiment of the present invention in some embodiments, it should be understood that the present invention is not necessarily limited in its application to the structural details and array of components and / or methods described in the following description and / or shown in the drawings and / or examples. Other embodiments of the present invention are possible or can be practiced or carried out in various ways.

[0183] Referring to the drawings, Figure 1A shows a schematic diagram of an exemplary automatic wiring system according to several embodiments of the present invention.

[0184] In some embodiments, the system includes electrical design software used in one or more of the following electronic devices 102, such as a personal computer, tablet, mobile phone, and dedicated design station. For simplicity, the software and electronic devices will henceforth be referred to as the design console.

[0185] In some embodiments, the system includes a database 104 having one or more of the following: technical electrical data, electrical designs, mechanical drawings, business data, etc.

[0186] In some embodiments, the system includes one or more automatic electrical wiring units / systems / modules 106, which will be described further below.

[0187] In some embodiments, the software on the electronic device 102, the database 104, and one or more automatic electrical wiring units / systems / modules 106 communicate with each other by one or more of the following: a wired connection, a wireless connection, and a wireless connection via a cloud server 108. In some embodiments, there is only one database 104 and one cloud server 108.

[0188] Example of a design console In some embodiments, the design console includes a graphical interface unit (GUI) dedicated to virtually designing the electrical cabinet. In some embodiments, the user inserts all necessary information and requirements related to the project, including one or more of the switches, knobs, and displays required, the demand for heat dissipation, radio frequency interference and electrostatic discharge protection, the required number of wires, connectors, and conduits, and the wire types. The wire information may include wire gauge, color, solar type, end piece type, etc., and the components within the cabinet may include various electrical and electronic components such as switches, circuit breakers, relays, couplers, drivers, computer components, and circuit boards.

[0189] In some embodiments, the design console 102 manages all design data, including bills of materials and connection lists, or related documents such as assembly instructions and datasheets. In some embodiments, a potential advantage of the design console is that its object-oriented data structure ensures that manufacturing instructions always match the design data. In some embodiments, the design console 102 communicates with a database 104 containing a component-based parts library, which ensures that only actual parts are used and optionally supports driving the design through automated parts selection.

[0190] In some embodiments, the design console 102 is configured to assist the user in creating multiple design drawings required for wiring the electrical cabinet. For example, an electrical circuit diagram showing where and what type of wires are connected within the electrical cabinet, and a mechanical drawing (typically performed by an electrician and / or mechanical engineer) showing a layout model of the various components within the electrical cabinet.

[0191] In some embodiments, the database includes a library of parts used and / or inserted into the library by previous users. In some embodiments, the parts library includes technical information about specific parts, each part being represented in one of the design drawings. For example, an electrician might use a specific part from the library (such as a circuit breaker) for a specific wire connection (shown in an electrical circuit diagram), and a mechanical engineer might use the location of a part to identify the physical location of a wire insertion point.

[0192] In some embodiments, the design console 102 is operated, for example, by a production engineer, who integrates both electrical circuit diagrams and mechanical drawings into a single design drawing, which is then used to operate an automated electrical wiring unit / system 106 for assembly. In some embodiments, the system itself automatically merges both design drawings and, optionally, provides them to the automated electrical wiring unit / system 106 for assembly after approval by the production engineer (or other dedicated personnel). In some embodiments, a simulation is further performed before the actual assembly by the automated electrical wiring unit / system 106. In some embodiments, data continuity is maintained throughout the entire process, from the creation of the cabinet design drawing, including the design and merging of electrical circuit diagrams and mechanical drawings, to the actual wiring of the cabinet, including the installation of components, the creation of the wire routing design drawing, and the actions performed by each component of the system. For further details on data continuity, the merging process, and other processes, please refer to www(dot)smart-cabinet-building(dot)com / en / index.jsp, the contents of which are incorporated herein by reference in their entirety.

[0193] In some embodiments, if there is no mechanical drawing and only a bill of materials (BOM) is available, an empty (unwired) cabinet can be scanned and analyzed using dedicated scanning software to recognize the type of cabinet and / or components. In some embodiments, the system then creates a wiring design based on the scan and the BOM.

[0194] In some embodiments, the design console 102 includes a “built-in real-time design rule checker” configured to check for errors and potentially prevent them. In some embodiments, a potential advantage of this feature is that it potentially avoids errors proactively, which is better than discovering errors later at the production stage. In some embodiments, the design console has basic functions including device duplication prevention, short-circuit prevention, design reuse by centrally stored subcircuits or modules, automatic and parallel connection, saving, loading, copying, rotating and mirroring of drawings and areas, extensive functionality for swapping symbols and components, a component-driven intelligent parts library, ensuring that only valid parts are used in the design, simple and complex transformations and option management, online cross-referencing of connections and devices, hyperlinks for objects and text, user-defined attributes, user-defined grid size, fonts and line types, and dynamic zoom and pan.

[0195] In some embodiments, the design console includes the design and documentation of wire diagrams and harness layouts. In some embodiments, the design allows for the combination of individual conductors to form new wires or harnesses. In some embodiments, shielding and twisted-pair structures can be added to the wires and automatically shown in the schematic. In some embodiments, the views allow for alternative documentation of devices, such as single-line diagrams, wiring diagrams, and wire diagrams. For example, a connector may be represented as a single pin in a schematic and as a complete connector in a wire diagram. In some embodiments, changing any of the views immediately updates all other views, ensuring that all documentation is synchronized.

[0196] In some embodiments, the design console includes a block function. In some embodiments, blocks represent components, rack equipment, black boxes, PCBs, and systems and subsystems throughout the entire hierarchy. In some embodiments, connector pins are dynamically added to blocks and signal information is displayed alongside them. In some embodiments, since blocks represent hierarchical systems and subsystems, users can tunnel down the blocks to lower levels, and signals and connections can be passed between levels and sublevels. In some embodiments, the hierarchy enables top-down and bottom-up design, facilitates design reuse, and provides administrators with a system-level overview. In some embodiments, special representations of connectors, such as those used in the aerospace and automotive industries, can be automatically created using dedicated extensions.

[0197] In some embodiments, the system includes instructions for validating the design according to specific standards and / or codes, such as ensuring that all grounding bars are properly positioned and sized according to, for example, state / national / CE / UL regulations.

[0198] Referring here to Figure 1B, a flowchart shows exemplary methods of merging an electrical circuit diagram with a mechanical drawing within and by the design console 102, according to several embodiments of the present invention. In some embodiments, the user provides and / or inserts rules for the electrical circuit diagram 120 and / or mechanical drawing 122 into the design console 102. In some embodiments, the rules are rules relating to one or more standards required by the government, special requirements by the client, technical limitations, and any other rules that the user wishes to add to the design console 102. In some embodiments, the user then designs the electrical circuit diagram 124 and / or mechanical drawing 126 in the design console 102 itself. In some embodiments, different designs are provided by different users and inserted independently into the design console 102. In some embodiments, the design is created elsewhere and manually inserted into the design console 102. In some embodiments, upon receiving the design, the design console 102 performs a check of the design to ensure that the design conforms to the established rules (128 / 130). In some embodiments, the system notifies the user if there is a problem with any part of the design. In some embodiments, the correction is made by the design console 102 itself. In some embodiments, the user brings in a corrected design created elsewhere. In some embodiments, once the design is approved, the design console 102 creates the original wiring diagram by merging the electrical circuit diagram and the mechanical drawing (132). In some embodiments, after merging, the design console 102 optionally performs additional checks on the rules of each design to ensure that all rules are still maintained (134). In some embodiments, the system then proceeds to prepare the robotic wiring diagram (136).

[0199] In some embodiments, the user inserts technical data for the electrical cabinet, including, for example, the length and number of DINs and the actual space dedicated to the elements of the electrical cabinet that require wiring. In some embodiments, the design console 102 includes instructions for checking and / or merging electrical circuit diagrams and / or mechanical drawings, taking into account the technical data for the electrical cabinet inserted by the user. In some embodiments, if the design console 102 finds inconsistencies and / or problems, it sends a message to the user. Optionally, the user can edit and re-check the design drawings.

[0200] In some embodiments, the design console allows for the transfer of electrical cable laying / wiring details (components, connectors, terminals, splices, and netlist information) to the automated electrical wiring unit / system 106.

[0201] In some embodiments, the design console allows for work in either two or three dimensions. In some embodiments, the design console enables the user to lay out components within a panel enclosure. In some embodiments, intelligent automatic snap points allow for easy placement of parts in the correct position, and lockout and height restrictions prevent damage. In some embodiments, a potential benefit of the system is providing an easy-to-use system, meaning the user does not need to potentially understand MCAD tools. In some embodiments, the software is configured to automatically create a design drawing of the wire route through the ducts in the panel, taking into account the shortest route and any separation requirements. In some embodiments, the duct filling capacity is also checked during design drawing creation. In some embodiments, the length of each wire is calculated, and this information is passed to an automatic electrical wiring unit / system 106.

[0202] In some embodiments, based on the designs and routing of multiple wires, cable placement priorities are generated based on one or more of the following examples: physical constraints (e.g., inserting wire 11 before wire 12 into a device to avoid collisions / obstacles), and sequence optimization based on other priorities (e.g., reducing cycle time).

[0203] In some embodiments, the design console uses a simplified model of the electrical panel design to check for collisions in the complete mechanical design. In some embodiments, this functionality allows a complete digital mockup to evaluate spacing requirements, collision / interference detection, and error prevention. In some embodiments, multiple users can utilize the system simultaneously, independently or collaboratively, at their discretion. In some embodiments, the design console ensures that all changes are tracked and documented. In some embodiments, alternative revisions of the design are compared with each other, and any changes are reported and stored in both graphical and textual formats. In some embodiments, manufacturing data is extracted from the design in wirelist format, including routing and length information to the automated electrical wiring unit / system 106.

[0204] Example of a simulation module In some embodiments, the design console includes a simulation module containing dedicated software with instructions for performing a virtual simulation of the performance of the electrical cabinet during and / or after the design process. In some embodiments, after the simulation is performed, an optimization process is performed according to and / or taking into account the simulation results.

[0205] In some embodiments, the simulation module performs simulations to potentially prevent collisions between the system (e.g., a robotic arm) and cabinet components. In some embodiments, the simulation module performs simulations to validate various sequences in order to select the sequence with the best cycle time. In some embodiments, the simulation module is used to validate the placement of all components included in the bill of materials (BOM) within the electrical cabinet. In some embodiments, the simulation module is used to validate that all design drawings are used for the wiring design of the electrical cabinet. In some embodiments, the simulation module is used before the automatic electrical wiring unit / system 106 is run. In some embodiments, the simulation module generates code and optionally downloads it to the automatic electrical wiring unit / system 106. In some embodiments, the simulation module is used to set the cost of cabinet assembly for the end user. In some embodiments, simulation is used to optimize the use of raw materials, for example, to minimize the total length of wire used to save copper.

[0206] An example of dividing a task into macro and micro processes. In some embodiments, the design console software includes instructions for dividing the entire automated routing process into multiple macro-processes, each containing multiple micro-processes. In some embodiments, an optimization process, including the use of simulation, ensures that macro- and micro-processes are executed in the most optimal way according to the task by optimizing most, but not all, of the macro- and micro-processes, at the discretion of the user. In some embodiments, the automated routing system may utilize micro and macro-behavioral analysis by AI algorithms to perform multiple optimization processes and reduce setup time. In some embodiments, the AI ​​algorithm is configured to analyze errors and / or recurring failures in routing performance and optionally correlate them with specific components and / or locations within the panel to provide solutions and / or warnings in advance when creating the routing diagram for the panel.

[0207] In some embodiments, the microprocess depends on the specific tools used, but similar macroprocesses can be used for different microprocesses for the actual devices within the automated electrical wiring unit / system 106.

[0208] In some embodiments, a microoperation library is part of a third-party entity that provides its corresponding microoperations to a tool. For example, if a gripper can be electrically operated, a microoperation can be provided that activates a motor (or, alternatively, a pneumatic actuator) to perform a gripping task. In some embodiments, the microoperation may include a sensing module for, for example, identifying that a wire is actually secured in place.

[0209] Example of an automatic wiring unit / system 106 In some embodiments, after the creation of the design drawings and / or design of the electrical cabinet, the final design is passed to an automated wiring unit / system 106 for assembly. In some embodiments, the electrical cabinet may be a panel, system, appliance, or any other device requiring wiring.

[0210] Referring here to Figures 2 and 3, a schematic diagram (Figure 2) and a schematic diagram (Figure 3) of an exemplary automatic wiring unit / system 106 according to several embodiments of the present invention are shown. In some embodiments, the exemplary automatic wiring unit / system 106 includes one or more modules as part of and / or inside the main casing 202, for example, a wire preparation module 204, one or more wiring arm modules 206, one or more wiring end effector modules 208, a panel handling module 210, a quality assurance (QA) module 212 (shown only in Figure 2), and a software module 214 (shown only in Figure 2).

[0211] Example of software module 214 In some embodiments, the automated wiring unit / system 106 includes all the different modules within the wiring unit / system 106, as well as a software module 214 that communicates with an external system. In some embodiments, the software module 214 receives a design drawing from a design console (external system) and activates the different modules within the automated wiring unit / system 106 to execute the wiring design drawing.

[0212] In some embodiments, the software module 214 also performs the functions of debugging the system and performing and / or scheduling system maintenance.

[0213] In some embodiments, the software module 214 includes, among other things, on-site simulation software that enables validation of the process (or a part thereof) before execution and during actual execution.

[0214] In some embodiments, the user can edit the runtime software to, for example, add new wires, edit the routes of existing wires, and / or omit wires. In some embodiments, wire parameters such as gauge and color may also be edited by the user. In some embodiments, the user can add test and / or QA routines to the runtime software.

[0215] Example of Panel Handling Module 210 In some embodiments, various panel handling modules can support the process of loading and unloading panels into and from the system 106. In some embodiments, the panel handling module 210 is configured to rotate an electrical cabinet around its axis within the automatic wiring unit / system 106 to facilitate one or more of the loading and unloading of the electrical cabinet, and to allow the electrical cabinet to be equipped while it is within the automatic wiring unit / system 106 with user access. In some embodiments, the panel handling module can hold the panel vertically (as shown in, for example, Figure 3) and / or horizontally (as shown in, for example, Figure 15).

[0216] In some embodiments, the panel handling module is used in combination with an automatic or semi-automatic loading / unloading system. In some embodiments, the loading / unloading system moves linearly rather than rotationally.

[0217] Example of QA Module 212 In some embodiments, the QA module 212 is configured to communicate with all modules of the automatic wiring unit / system 106 and to perform several actions to ensure that the functions of the automatic wiring unit / system 106 are valid. In some embodiments, the functions to be monitored are validating wire insertions, validating the position of electrical components in electrical cabinets, verifying wire routing, validating the operation of locking mechanisms in electrical connectors of electrical components (for example, by validating the torque of screws holding wires in the connectors), and optionally, one or more of validating wire connections and validating electrical integrity.

[0218] In some embodiments, the automated wiring machine may be equipped with multiple sensors for tactile, force, and moment / torque feedback, which may increase the likelihood of wires being inserted into the correct position and potentially reduce the time required for the validation process.

[0219] In some embodiments, a visual system and / or an optical system is used for QA. In some embodiments, various electrical circuits can be checked by applying various loads to the system, for example, by delivering current / voltage at different levels through two elongated extensions 910a-b (see below), or through specific tools that can be attached (automatically or manually) to the wiring arm module. For example, a locking actuation mechanism that operates a locking mechanism in a connector includes a screwdriver that acts on a screw to press a wire. In some embodiments, a continuity / resistance test is performed by using current to touch, for example, two components (one on each arm) and validating continuity by resistance and / or current parameters.

[0220] In some embodiments, the automated wiring system may increase the accuracy of wire position validation and insertion at appropriate locations by utilizing deep learning algorithms for component positioning and identification, potentially reducing the time required for the validation process.

[0221] In some embodiments, some components may be partially hidden (or only partially visible) from the QA system, so the system's deep learning (D / L) algorithm uses previously learned processes to identify the parts and estimate their locations.

[0222] In some embodiments, for example, if a particular connector normally directs the ground wire to port A, but a certain instruction set causes the ground wire to be (incorrectly) routed to port B, the D / L algorithm is used to predict the error that may occur in the routing system, and the system issues a warning, or alternatively, uses other logic to check whether port B can also accept the ground wire.

[0223] In some embodiments, the automatic wiring system is controlled by impedance control. The possibility of using reinforcement learning to insert flexible wires to increase the accuracy of inserting them into appropriate positions. There is.

[0224] In some embodiments, the automated wiring system uses a search routine with a feedback system to locate openings (ports) for inserting wires into connectors of components. In some embodiments, the automated wiring system uses a visual system, with or without other sensors, to locate connector openings within components before and / or during wire insertion. In some embodiments, the automated wiring system performs a dry run (scan) on the components to validate the location of connector openings within the components (using various sensors such as visual, optical, and tactile), provide a corrected delta position, and then executes the insertion routine.

[0225] Wire preparation module 204 Referring here to Figure 4, schematic diagrams of exemplary wire preparation modules 204 according to several embodiments of the present invention are shown. In some embodiments, the automatic wiring unit / system 106 includes the wire preparation module 204. In some embodiments, the wire preparation module 204 is an integral part of the automatic wiring unit / system 106. In some embodiments, the wire preparation module 204 is an independent module located outside the automatic wiring unit / system 106, which is optional. In some embodiments, the wire preparation module 204 is responsible for preparing wires for integration into an electrical cabinet by the automatic wiring unit / system 106.

[0226] In some embodiments, the wire preparation module 204 includes one or more of the following components: a plurality of wire stocks 402, one or more wire manipulators 404 (see below) having rails 410 that allow the wire manipulators 404 to move between modules, at least one wire stripper module 406, a plurality of wire end connector (wire head) mounting modules 408, a wire cutter 414, and a frame 412 configured to house all the modules and components of the wire preparation module 204.

[0227] In some embodiments, the wire preparation module 204 includes a wire marking device configured to add individualized markings to wires being prepared. For example, the wire marking device can add numbers, letters, symbols, etc., by laser, sticker, or any other printing machine configured to print on the surface of the wire or to add stickers or sleeves to mark the wire. In some embodiments, a potential advantage of the wire marking device is that it makes it potentially easier to find specific wires in the cabinet later.

[0228] Example of frame 412 In some embodiments, the wire preparation module 204 comprises a frame 412 configured to house all modules and components of the wire preparation module 204. In Figure 4, the frame 412 is a vertical frame. For ease of understanding of the invention, the following description refers to a vertical frame as shown in Figure 4. It should be understood that other configurations of the wire preparation module 204 in general, and specifically the configuration of the frame 412 (see, for example, the exemplary horizontal automatic wiring cabinet below), are still within the scope of the invention. In some embodiments, a potential advantage of having a vertical frame is that it allows for the positioning of different components of the wire preparation module 204 in a sequence manner, which also facilitates the movement of wires by the wire manipulator 404 during the wire preparation process. In some embodiments, the length of the frame 412 determines the maximum length of the rail 410.

[0229] Example of Wire Manipulator 404 In some embodiments, the wire manipulator 404 is configured to grasp the first distal end of the required wire from the wire stock 402 and transport it first to a wire stripper module 406. In the wire stripper module, the first distal end is stripped, exposing the wire core, and then optionally transported to one of a plurality of wire end mounting connectors 408, where a connector is attached to the previously exposed wire core. In some embodiments, the exposed wire core is left exposed for insertion into an electrical cabinet. In some embodiments, if the required length of wire is shorter than the maximum distance between two wire manipulators 404, which is determined by the length of the rail 410 (determined by the length of the frame 412), in the example disclosed in Figure 4, the first wire manipulator pulls out the required amount of wire by moving upward relative to the frame 412 and the wire stock 402, and the second wire manipulator picks up the second distal end of the wire, transports it to a wire cutter 414, and cuts the wire, thereby creating a feed distal end of the wire. In some embodiments, as performed at the first distal end, the second wire manipulator first transports the second distal end to a wire stripper module 406, where it strips the second distal end to expose the wire core, and then transports it to one of a plurality of wire end mounting connectors 408, thereby mounting the connector onto the exposed wire core.

[0230] In some embodiments, the stripped wire itself may be marked by a wire marking device, either before or after attaching wire end connectors to the stripped wire, as disclosed above.

[0231] In some embodiments, the wire stock moves laterally to position various wires within the feed area. In some embodiments, the wire stock may include a plurality of different wire reels, e.g., about 5 to about 10 different wire reels, optionally about 5 to about 20 different wire reels, optionally about 5 to about 50 different wire reels, e.g., 5, 8, or 20 different wire reels. In some embodiments, the reels may be changed manually or automatically for different electrical cabinet assemblies.

[0232] Referring here to Figures 5A-B, schematic diagrams of exemplary wire manipulators 404 according to several embodiments of the present invention are shown. In some embodiments, the wire manipulator 404 includes a wire holder 502 configured to reversibly hold the end of a wire during the wire preparation process. In some embodiments, the wire holder includes two elongated elements 504 / 506 configured to open and close to hold the end of a wire between them. In some embodiments, the force applied to hold the end of the wire between the two elongated elements is about 0.5 N to about 5 N. In some embodiments, the wire holder 502 includes one or more force sensors configured to monitor the force applied to the wire. In some embodiments, optionally, other sensors such as torque sensors, optical sensors, and / or conductivity / capacitance sensors are used to validate the interaction between the wire and the gripper. In some embodiments, the wire holder 502 is connected to a wire holder base 508. In some embodiments, the wire retaining base 508 includes a rotating mechanism configured to allow rotation along the X-axis 510 of the wire holder, for example, as indicated by arrow 512 in Figure 5B (see XYZ coordinate image). In some embodiments, a compliance miniature mechanism holds the wire retaining base 508 to provide protection against misalignment during insertion. In some embodiments, the wire retaining base 508 is connected to a movable element 514 configured to move along the Y-axis beyond the connector 518, as indicated by arrow 516 in Figure 5A. In some embodiments, the connector 518 is mounted on a second base 520 configured to move along the Z-axis (up and down) on the rail 410.

[0233] In some embodiments, as can be understood from the above paragraphs, the wire manipulator 404 rotates the wire holder 502 along the X-axis 510 to pick up the end of the wire from the wire stock 402, and then rotates the wire holder 502 back so that the just-picked-up end of the wire faces these modules and the components of the wire preparation module 204. In some embodiments, the end of the wire is inserted into each of the modules using the movable element 514. This movable element is configured to insert and extract the end of the wire from the module by moving along the Y-axis. In some embodiments, the wire is moved along different modules by moving the second base 520 along the Z-axis (vertically) on the rail 410.

[0234] Example of wire stripper module 406 In some embodiments, the wire stripper module is configured to automatically strip the coating (usually plastic or other material for insulation) from the end of the wire and expose the wire core (usually made of a metal wire). In some embodiments, additionally or alternatively, a programmable stripping knife is used to strip the wire coating.

[0235] Example of wire end connector (wire head) attachment module 408 In some embodiments, the wire end connector attachment module is configured to receive the stripped end of the wire and automatically attach a connector / wire head, such as also known in the art as a ferrule. The wire connector / wire head is known in the art and can be, for example, one or more of a ring connector, a spade connector, and a blade connector.

[0236] Example of wire cutter 414 In some embodiments, the wire cutter is configured to cut the wire.

[0237] Example of wire stock 402 In some embodiments, the wire preparation module 204 comprises multiple wire stocks 402. In some embodiments, the wire stocks include multiple different types of wires used in electrical cabinets, e.g., shielded wire, wires of different gauges, wires of different colors, and / or different types of insulators, such as those for RF. In some embodiments, optionally, the wire stocks are coupled to an automatic feeder configured to release as much wire as needed, e.g., configured to release the required length of wire as needed. In some embodiments, a labeling module 409 is added to the wire preparation module for marking the wires. In some embodiments, labels can be printed on a sleeve and inserted onto the wire before the end piece. In some embodiments, the printed label is attached to the wire (called a flag). In some embodiments, the indication is printed directly onto the wire.

[0238] Example of wire preparation method Referring here to Figures 6A-C, flowcharts of exemplary wire preparation methods according to several embodiments of the present invention are shown. In some embodiments, the system receives information about the wire to be prepared (602). In some embodiments, the information about the wire includes one or more of the wire type and wire length. In some embodiments, a first wire manipulator grasps the end of the selected wire (604). In some embodiments, the first wire manipulator strips the insulation from the wire core and exposes the wire core by moving the end of the wire into a stripper module 406 (606). In some embodiments, optionally, the first wire manipulator attaches a wire end connector / wire head to the stripped wire core by moving the stripped end of the wire into an associated wire end connector mounting module 408 (608). In some embodiments, optionally, the first wire manipulator marks (609) and / or provides identification to the wire by moving the end of the wire into a labeling module 409.

[0239] In some embodiments, as described above, the maximum distance between the two wire manipulators 404 is determined by the length of the frame 412, which limits the length of the rail 410 used for the movement of the wire manipulators 404 along the Z axis.

[0240] In some embodiments, the system evaluates whether the length of the wire is within a predetermined maximum length (610) set according to the maximum distance between the two wire manipulators 404.

[0241] In some embodiments, if the answer is "yes" (following the letter "A" in Figure 6B), the wire manipulator holding the wire to which the wire end connector has just been attached moves itself to a distance necessary to provide the required length of wire from the second wire manipulator (612). In some embodiments, the second wire manipulator picks up the wire and a position selected according to the required length (614). In some embodiments, the second wire manipulator moves the wire towards the wire cutter 414, which creates a second end of the wire by cutting the wire (616). In some embodiments, while the wire cutter is cutting the wire, the second wire manipulator continues to hold the previously cut end of the wire. In some embodiments, the second manipulator strips the insulation from the wire core and exposes the wire core by moving the second end of the wire into the stripper module 406, just as was done with the first end of the wire (618). In some embodiments, optionally, a second wire manipulator mounts a wire end connector onto the stripped wire core by moving the stripped second end of the wire into the associated wire end connector / wire head mounting module 408 (620). In some embodiments, optionally, the second wire manipulator marks the wire by moving the end of the wire into the labeling module 409 (621) and / or provides a second identification. In some embodiments, at this point, there is a wire having two ends with the required connectors, held by two different wire manipulators. In some embodiments, at this point, the wire ends are delivered to a wiring arm module for further insertion into a wire cabinet (622) (further detailed below).

[0242] Returning to Figure 6A, if the answer is "no" (following the letter "B" in Figure 6C), the wire manipulator, holding the wire to which the wire end connector has just been attached, delivers the first end to the wiring arm module (624), and uses both arms of the wiring arm module to pull the wire to the required length (608). In some embodiments, when this length is reached by either the first or second wire manipulator, either of them grasps the wire and a position selected according to the required length (630). In some embodiments, the first / second wire manipulator moves the wire toward the wire cutter 414, which creates a second end of the wire by cutting it (632). In some embodiments, while the wire cutter is cutting the wire, the first / second wire manipulator continues to hold the previously cut end of the wire. In some embodiments, the first / second manipulator strips the insulation from the wire core and exposes the wire core by moving the second end of the wire into the stripper module 406, as was done at the first end of the wire (634). In some embodiments, optionally, the first / second wire manipulator mounts a wire end connector onto the stripped wire core by moving the stripped second end of the wire into the associated wire end connector mounting module 408 (636). In some embodiments, optionally, the first / second wire manipulator marks the wire by moving the end of the wire into the labeling module 409 (637) and / or provides identification. In some embodiments, at this point, there is a wire with two ends equipped with the required connectors, one end held by the wiring arm module and the second end held by the first / second wire manipulator. In some embodiments, at this point, the second wire end is delivered to the wiring arm module for further insertion into the wire cabinet (as further detailed below).

[0243] Example of a wire delivery unit In some embodiments, wires are provided that are ready for use by providing pre-cut wires that are ready to be wired into an electrical cabinet. In some embodiments, the pre-cut wires are obtained directly from a third party. In some embodiments, the pre-cut wires are prepared by a wire preparation module. In some embodiments, the wires ready for use are placed within reach of a mechanical arm module. In some embodiments, when pre-cut wires are used and made available to a mechanical arm module, the use of a wire delivery unit is referred to as providing wires to be inserted into an electrical cabinet by an automated system. In some embodiments, the pre-cut wires are presented to the system using a dedicated fixture, for example, the fixture is constructed to hold the wires according to their length or order / sequence. In some embodiments, optionally, the wire delivery unit is movable and can be mounted to the system as needed. In some embodiments, optionally, the wire delivery unit can serve multiple systems. In some embodiments, the wire preparation module includes a handover mechanism that delivers and / or presents wires to a wiring system, for example, using a manipulator, dual arms, pneumatic shaft, etc.

[0244] Fine motor skills and wiring Before detailing at least one embodiment of the exemplary wiring arm module 206 and exemplary wiring end effector module 208 of the present invention, the inventors wish to convey one of the many challenges that can be conceivable in robotic automation performance in general, and more specifically in robotic automation of electrical wiring and robotic wiring operations. The inventors have found that proper wiring of electrical wires to an electrical cabinet requires a certain level of dexterity and / or perceptual ability (meaning a high level of wire handling ability), and obviously in some cases, at least two hands are required. For example, the technician and / or user needs to use the somatosensory system (e.g., touch) to hold the wire with one hand and insert the wire as is, or with the wire head attached, into the electrical outlet or electrical terminal connector of the component, and perform a locking action with the other hand to lock the wire into the outlet. The terms “electrical outlet” and “electrical terminal connector” are interchangeable, and when referring to either, it should be understood that both refer to the same thing, which is an object within the component configured to accept wires for the purpose of connecting and / or holding electrical wires to the component. Furthermore, depending on the type of wire end, when inserting the wire into an outlet, it is necessary to use only the required force to lock and hold the wire in place while simultaneously avoiding deformation of the wire due to excessive force. It is also common in this art for the user to "feel" that the wire is secured in place by slightly pulling on it after the locking action has been performed. The following paragraphs describe exemplary actions performed by humans to enable those skilled in the art to understand the challenges involved in translating seemingly simple human tasks into robotics.

[0245] In some embodiments, the robotic system has fine motor skills (or dexterity). In some embodiments, the automated wiring system (generally) and wiring arm module of the present invention have one or more of the following technical characteristics:

[0246] Joints: In some embodiments, the arm module, together with the wiring end effector module, comprises multiple joints that give the system multiple degrees of freedom of motion. Referring here to Figure 7A, an exemplary wiring arm module 206 including multiple joints according to some embodiments of the present invention is schematically shown. In some embodiments, the wiring arm module 206 comprises multiple joints 702, 704, 706. In some embodiments, the joints give multiple degrees of freedom of motion. For example, joints 702, 704, 706 can potentially give between 4 and 8 degrees of freedom of motion, as indicated by the arrows. It should be understood that the joints disclosed herein are merely examples to enable those skilled in the art to understand the present invention, and more or fewer joints may be used. In some embodiments, the system may be a Cartesian coordinate system with a rotary end effector, or it may be fully articulated.

[0247] Exemplary perceptual capabilities: In some embodiments, the arm module and wiring end effector module include multiple sensors (see below) configured to monitor the interaction between the module and the wire and / or wire cabinet. In some embodiments, the arm module and wiring end effector module operate using a combination of motors, sensors, and software that enables a compliance-based mechanism with antagonistic elastic action, as opposed to a rigid linkage-based robotic gripper. In some embodiments, this allows for greater variability in gripping force control. In some embodiments, the software includes information on payload weight / stiffness and structure, as well as programs to enhance the correct function of the gripper (grasp design) without overshoot.

[0248] In some embodiments, parts of the arm and / or gripper may be automatically modified to suit specific tasks, such as holding different tools like tweezers or cutters.

[0249] Grip and sliding function: When humans perform wiring actions, they use tactile feedback to secure the cable to the connector / device, and a typical action cycle includes the following (see Figures 7B1-7B5): • The wire is gripped by applying a radial force (radial force, Figure 7B1) to the wire during insertion, and then applying an insertion force (axial force, Figure 7B2), before the contact force increases during insertion, which is initially zero. • At a certain peak force (determined by user experience), a person "feels" that the wire is inserted into the component's connector (peak force, Figure 7B3). Typically, at this point, the axial force is canceled out by fully inserting the wire into the component's connector; After the wire is secured to the connector, the user pulls the wire back with a certain amount of force (to feel if it is securely fastened, Figure 7B4); Next, the user reduces the radial force (gripping force) applied to the cable, allowing it to slide axially in the hand (Figure 7B5). Typically, the user can feel the cable sliding without releasing the wire.

[0250] In some embodiments, these actions are performed using functions referred to herein as gripping and sliding functions.

[0251] In some embodiments, the wiring arm module 206, which includes the wiring end effector module 208, includes multiple motors and sensors that perform force and axial and radial force measurements, similar to human actions, in order to provide a system with a high level of dexterity and perceptual ability to perform wiring actions. In some embodiments, the wiring end effector module 300 includes one or more optical sensors, e.g., one or more cameras and / or laser scanners. In some embodiments, the wiring end effector module 300 includes multiple 2D cameras and / or 3D cameras.

[0252] Example of wiring arm module 206 Referring now to FIGS. 8A - B, there is shown a schematic view of an exemplary wiring arm module 206, according to some embodiments of the present invention. In some embodiments, the wiring arm module comprises a base 802 mounted on a rail 804. In this example, the rail 804 comprises two vertical tubes, on which the entire wiring arm module moves vertically, as schematically indicated by arrow 806. In some embodiments, a mechanical arm 808 mounted on the base 802 comprises a plurality of arm portions 810, 812 and joints 702, 704, 706. In some embodiments, at the end of the mechanical arm 808 there is a wiring end effector module 208. Referring now to FIG. 8B, there is shown a schematic view of two exemplary wiring arm modules 206 within a wiring unit / system 106, according to some embodiments of the present invention. In some embodiments, each wiring arm module 206 is located on a side of the wiring unit / system 106. In some embodiments, a potential advantage of providing them in this way is to provide the space required for each mechanical arm to move freely without interfering with the movement of other mechanical arms. In some embodiments, each wiring arm module 206 comprises a wiring end effector module 208, optionally including a camera 850. It should be understood that in any of the embodiments of the wiring end effector module 208, a camera may be optionally added.

[0253] In some embodiments, the wiring arm module is optional, which means that a simpler holder for the wiring end effector module 208 can be used. In the following paragraphs, the present invention will be described using an example of an automatic wiring system comprising a dedicated wiring arm module 206. It should be understood that other types of platforms that can operate the wiring end effector module 208 can be used and are also included within the scope of the present invention.

[0254] In some embodiments, a typical arm has a payload of approximately 10 kg and an accuracy of better than 0.1 mm. In some embodiments, an orthogonal gantry arm or a dual arm is used for the primary motion (XYZ), and fine local motion is performed by two or three rotational axes together with an end effector.

[0255] Example of wiring end effector module 208 Referring here to Figure 9A, a schematic diagram of an exemplary wiring end effector module 208 according to several embodiments of the present invention is shown. In some embodiments, the wiring end effector module 208 comprises one or more of the following components: a wire holding element 902 and a wire locking element 904. Referring here to Figure 9B, a schematic diagram of the components of the wire holding element 902 according to several embodiments of the present invention is shown. In some embodiments, the wire holding element 902 comprises one or more of a base 906 including a wire clamping element 908. In some embodiments, the wire clamping element 908 comprises two extensions 910a-b, and optionally two elongated finger-like extensions, which are connected, for example, by an electrical mechanism 912 and / or a pneumatic mechanism. In some embodiments, the wire clamping element 908 comprises a gimbal block 970 connecting the two extensions 910a-b (see further description of the gimbal block 970 below). In some embodiments, the base 906 includes a motor 914 that enables horizontal movement of the wire holding element 902 in the direction schematically indicated by arrow 916. In some embodiments, alternatively, or further, the wiring arm module provides movement along schematic arrow 916. In some embodiments, the horizontal movement indicated by arrow 916 is in the direction toward the electrical terminal connector along the axis of the wire. In some embodiments, the movement is along the wire terminal port, which may be at angles of 30, 45, 90 degrees (or any angle in between) from the plane of the panel.

[0256] Referring here to Figure 9C1, schematic diagrams of sensors located on elongated extensions 910a-b according to several embodiments of the present invention. In some embodiments, one or more of the elongated extensions 910a-b include one or more sensors 918 configured to monitor the force applied to the wire 920 by the elongated extensions 910a-b. In some embodiments, the sensors are embedded in the finger portion or body of the end effector. In some embodiments, these sensors provide the system with a high level of dexterity and perceptual ability to perform wiring actions similar to those performed by a human, as axial and radial forces are measured as described above. In some embodiments, the sensors are based on, for example, strain gauges, load cells, and / or other such things. In some embodiments, further or alternatively, a mechanism capable of sensing force or moment (i.e., a sensor) is located on a component connecting the extensions to the device, such as a gimbal block (see 970 in Figure 9C2), as shown and described below in Figures 9C2-9C3.

[0257] In some embodiments, the wire holding element 902 receives the wire from the wire manipulator 404 of the wire preparation module 204 and is responsible for holding the wire.

[0258] In some embodiments, the elongated extensions 910a-b can be automatically and / or manually replaced to accommodate different wire gauges.

[0259] In some embodiments, the electrical mechanism 912 includes a collision prevention mechanism to protect the finger portion.

[0260] In some embodiments, the electrical mechanism 912 includes a sensor capable of measuring a moment applied by the elongated extensions 910a-b during insertion, for example, a moment with a value of about 0.01 NM to about 0.1 NM.

[0261] Referring now to Figures 9C2-9C3, schematic diagrams of exemplary gimbal blocks to which extensions are connected are shown according to several embodiments of the present invention. In some embodiments, the gimbal block 970 comprises several components that enable monitoring of forces applied to extensions 910a-b. In some embodiments, the several components are one or more gimbals that are mounted overlapping each other but have different axes of motion. For ease of explanation, we will discuss two axes of motion. It should be understood that by using more gimbals, it is possible to provide three or more axes of motion that can be monitored. These are also part of the scope of the present invention. Returning to Figure 9C2, the gimbal block 970 comprises a top block 972 that connects the gimbal block 970 to the rest of the device. In some embodiments, a top connector 974 is located below the top block 972 and is connected to the top block 972 by screws 976, etc. In some embodiments, one or more damping springs 996 that communicate with one or more button axis load cells 978 are housed between the top block 972 and the top connector 974. In some embodiments, the load cell calibration is performed by acting on a damping force calibration set screw 980. In some embodiments, a central block 982 is located below the top connector 974. In some embodiments, a first gimbal shaft 984 is inserted into the top side of the central block 982, giving a horizontal axis of motion perpendicular to the pin of the first gimbal shaft 984 (see the description below for the motion of the gimbal block). In some embodiments, a second gimbal shaft 986 is inserted into the bottom side of the central block 982 (indicated by the insertion position). In some embodiments, the second gimbal shaft 986 is perpendicular to the first gimbal shaft 984. In some embodiments, the second gimbal shaft 986 gives a horizontal axis of motion perpendicular to the pin of the second gimbal shaft 986 (see the description below for the motion of the gimbal block). In some embodiments, a bottom connector 988 is located below the central block 982, connected to the central block 982 at the top and to the bottom block 990 at the bottom.In some embodiments, although not shown in Figure 9C2, one or more damping springs of another set relating to / interfacing with one or more button axis load cells of another set are housed between the bottom connector 988 and the bottom block 990. In some embodiments, extensions 910a-b are connected to the bottom block 990.

[0262] In some embodiments, the device comprises a single gimbal block 970 connecting both extensions 910a and 910b. In some embodiments, the device comprises two gimbal blocks 970, with one gimbal block 970 for each extension, as shown, for example, in Figure 9C3.

[0263] Referring here to Figure 9C3, exemplary motion of a gimbal block 970 and schematic diagrams of exemplary embodiments of a device comprising two gimbal blocks according to several embodiments of the present invention. In some embodiments, as described above, the gimbal block 970 comprises a first gimbal axis 984 that gives motion of the gimbal block 970 on a first axis and a second gimbal axis 986 that gives motion of the gimbal block 970 on a second axis. Figure 9C3 shows a side view of the gimbal block 970, showing motion enabled by the first gimbal axis 984 (arrow 992). Furthermore, Figure 9C3 shows a front view of the gimbal block 970, showing motion enabled by the second gimbal axis 986 (arrow 994). In some embodiments, the first gimbal axis 984 and the second gimbal axis 986 provide the gimbal block 970 with two axes of rotation at different positions. In some embodiments, these axes of rotation are used in conjunction with a single-axis load cell to measure the moment and force applied to the extension. In some embodiments, as shown in Figure 9C3, the two extensions are each separately connected to the gimbal block 970, allowing for the measurement of different forces acting on each extension. In some embodiments, when the gimbal mechanism reaches its rotational (motion) limit, which optionally implicitly accesses the forces applied to the extensions (e.g., during a possible collision between the device and an electrical panel), the system may stop the wire insertion operation and / or take corrective action (movement of the device).

[0264] Referring here to Figure 9D, a schematic diagram of an exemplary wire locking element 904 according to several embodiments of the present invention is shown. In some embodiments, the wire locking element is configured to interact with a wire locking mechanism of the component after the wire has been inserted into the respective electrical terminal block of that component in a wire cabinet. In some embodiments, the components used in the cabinet may include different types of locking mechanisms within the connector, such as screw terminals, push buttons, and / or push-in mechanisms. In some embodiments, when a component is used that has an electrical terminal connector including a push-in locking mechanism, the wire locking element 904 is not needed and is therefore not used. In some embodiments, screw terminals or screw terminal blocks (components) secure the wire to a conductor in the terminal block (component) by tightening a screw to close the clamp. In some embodiments, push-button terminal blocks secure the wire to a conductor by a spring clamp that opens when a button is pressed. In some embodiments, when the button is released, the spring tightens on the wire with the clamp. In some embodiments, a push-in terminal block, as well as a push-button with a spring clamp, allows the wire to be pressed directly into the housing without using a push button to release the spring. In some embodiments, depending on the type of locking mechanism within the terminal block (component), the wire locking element 904 is equipped with a dedicated actuator 922. For example, in Figure 9D, the wire locking element 904 is equipped with a flathead screwdriver 922 used to secure the screw terminal block. In some embodiments, the head of the actuator and / or drill bit 322 can be replaced manually or, optionally, automatically (for example, by using vertical movement 330 to move the device toward a replacement rack that replaces the head of the actuator 322). Referring now to Figure 9E1, a schematic diagram is shown of several possible interactions between the wiring end effector module 208 and different types of terminal blocks (components) having different locking mechanisms for wires within the connectors of the components.

[0265] Returning to Figure 9D, in some embodiments, the wire lock element 904 includes a motor 924 configured to actuate a dedicated actuator 922. In some embodiments, the motor 924 and the dedicated actuator 922 are held by a base 926, which is further connected to a second motor 928, which performs a vertical movement as schematically shown by arrow 930, necessary for inserting the dedicated actuator 922 into the terminal block. In some embodiments, although not shown in Figure 9D, multiple motors are used to provide the wire lock element 904 with multiple directions of motion. In some embodiments, the wire lock element 904 is configured to move in the vertical, lateral, and longitudinal directions. In some embodiments, a potential advantage of giving the lock element 904 such freedom of motion is that multiple electrical terminal connectors and devices, each having different positions for accessing the wire lock mechanism, can interact.

[0266] In some embodiments, the wire locking element 904 includes a torque sensor, which is configured to monitor the torque force applied by the actuator to the locking mechanism of the electrical terminal connector within the component. In some embodiments, the system includes a database in which specific torque forces associated with a particular locking mechanism of the electrical terminal connector are stored. In some embodiments, the system includes commands for operating the actuator according to specific parameters, which are specifically matched to the torque requirements of a particular locking mechanism of a particular electrical terminal connector and a particular wire gauge.

[0267] Examples of using wires with end terminals (wire heads) ferrules. Referring here to Figures 9E2-9E3, schematic diagrams of ferrules according to several embodiments of the present invention are shown. In some embodiments, the wire used in an automatic wiring system is a wire (ferrule wire head) having a built-in ferrule at its distal end. The ferrule is a ring or cap 9002 having optionally a metal distal end 9004, which is used to enclose the exposed distal end of the wire, facilitating the handling of the distal end of the wire and its connection to the electrical terminal connector of the component. In some embodiments, the ferrule is rigid. In some embodiments, the ferrule is rigider than the wire itself. In some embodiments, the ferrule is between about 2 and about 10 times rigider than the wire. In some embodiments, the ferrule can have different dimensions, as shown, for example, in Figure 9E2. In some embodiments, the ferrule can have a metal part 9004 of different shapes at its distal end, as shown, for example, in Figure 9E3. In some embodiments, the ferrule is equipped with a cap 9002 that is stiffer than the wire itself, so the wiring end effector module 208 clamps the cap 9002 instead of directly clamping the wire. In some embodiments, a potential advantage of clamping the cap 9002 is that it facilitates the handling of the wire while inserting it into the electrical terminal connector of the component. Because the wire is flexible, if the wire bends during insertion, the head of the wire that needs to be inserted into the electrical terminal connector may be deflected. Clamping the cap 9002 may help avoid this. In some embodiments, the ferrule is configured to be fully inserted into the electrical terminal connector of the component, meaning that for a proper connection to be made, the cap 9002 must be fully inserted inside the electrical terminal connector of the component. In some embodiments, the method of inserting the wire into the electrical terminal connector of the component while using the wire with the ferrule includes additional steps, as further disclosed below.In some embodiments, additional actions that may need to be performed during the insertion of a wire including a ferrule include one or more of the following: partial insertion of the ferrule into the electrical terminal connector of the component, release or partial release of the ferrule, moving the device backward, re-clamping the wire at a distal position relative to the ferrule, and completion of the insertion of the wire and ferrule into the electrical terminal connector of the component. In some embodiments, before releasing the ferrule, the system optionally partially closes the locking mechanism of the electrical terminal connector in the component to partially hold the ferrule in place and potentially prevent the ferrule from coming out of the electrical terminal connector. In some embodiments, after re-clamping the wire and before further insertion of the wire into the electrical terminal connector, the system releases the locking mechanism of the electrical terminal connector to allow further insertion of the wire into the electrical terminal connector. In some embodiments, the wiring end effector module 300 includes an additional element configured to hold the wire in place while the extension moves to a more distal position on the wire. In some embodiments, the additional element may be a third extension configured to extend as needed and hold the wire in place.

[0268] In some embodiments, the extension / end effector allows for the insertion of ferrules with complex shapes, such as fork-shaped or ring-shaped ferrules, into the connector.

[0269] Referring here to Figure 9F, a flowchart of an exemplary wiring method using an exemplary wiring end effector module 208 according to several embodiments of the present invention is shown. In some embodiments, the elongated extension grips the wire by applying a radial force to the wire (950). In some embodiments, the force applied to the wire is about 5N to about 15N, optionally about 7N to about 20N, optionally about 8N to about 25N, e.g., about 8N, about 10N, about 12N. In some embodiments, the resolution of any of the above forces is about 1N. In some embodiments, the effector module brings the wire closer to the connector by applying an axial force (952). In some embodiments, the force applied to the wire is about 5N to about 15N, optionally about 7N to about 20N, optionally about 8N to about 25N, e.g., about 8N, about 10N, about 12N. In some embodiments, the resolution of any of the above forces is about 1N. In some embodiments, the wire is then inserted into a hole in the connector of the component (954). In some embodiments, the system senses resistance on the wire by the fact that the wire has reached the end of the hole in the connector (956). In some embodiments, the system then secures the wire within the connector of the component (958) (see the above method for securing the wire within the connector). In some embodiments, the system then pulls the wire back by applying a light axial force in the opposite direction, while sensing resistance from a gabbing sensor, to evaluate the firm connection of the wire within the connector (960). In some embodiments, the system slightly reduces the radial force on the wire while continuing to hold the wire (962). In some embodiments, the method ends if the insertion of the wire was the last wire to be connected to a component in the electrical cabinet. In some embodiments, the system allows the wire (still held by the elongated extension) to slide into the elongated extension without releasing the wire, while moving the mechanical arm away from the connector (964). In some embodiments, the system proceeds with the wiring process as described elsewhere (966).

[0270] Referring here to Figure 9G, a flowchart is shown illustrating an exemplary wiring method by an exemplary wiring end effector module according to several embodiments of the present invention, where the wire includes a ferrule. In some embodiments, the extension grips the wire by applying a radial force to the ferrule (9006). In some embodiments, the force applied to the ferrule is about 3N to about 110N, optionally about 7N to about 20N, optionally about 8N to about 25N, e.g., about 8N, about 10N, about 12N. In some embodiments, the resolution of any of the above forces is about 0.5N. In some embodiments, the effector module brings the ferrule closer to the connector by applying an axial force (9008). In some embodiments, the force applied to the wire is about 3N to about 15N, optionally about 7N to about 20N, optionally about 8N to about 25N, e.g., about 8N, about 10N, about 12N. In some embodiments, the resolution of any of the above forces is about 0.25N. In some embodiments, the ferrule is then partially inserted into the hole of the connector of the component (9010). In some embodiments, optionally, the system partially closes a locking mechanism in the electrical terminal connector to hold the ferrule in place (9012). In some embodiments, the wire with the ferrule is held in place (9014). In some embodiments, this is done by one or more additional elements disclosed above. In some embodiments, an extension is actuated to release the ferrule (9016). In some embodiments, the device then moves backward along the wire (9018). In some embodiments, the extension re-grabs the wire itself (9020). In some embodiments, optionally, the system opens the pre-partially closed locking mechanism of the electrical terminal connector (9022). In some embodiments, the system then applies an axial force to the ferrule, which is fully inserted into the electrical terminal connector (9024). The flowchart follows Figure 9H after letter A. In some embodiments, the system senses resistance on the wire by the fact that the wire has reached the end of the hole in the connector (9026).In some embodiments, the system then secures the wire within the connector of the component (9028) (see the method for securing the wire within the connector described above). In some embodiments, the system then pulls the wire back by lightly applying an axial force in the opposite direction, while sensing resistance from the gabbing sensor, to assess the firm connection of the wire within the connector (9030). In some embodiments, the system slightly reduces the radial force on the wire while continuing to hold it (9032). In some embodiments, the method ends if the insertion of the wire is the last wire to be connected to a component in the electrical panel. In some embodiments, the system allows the wire (still held by the elongated extension) to slide into the elongated extension without releasing the wire, while moving the mechanical arm away from the connector (9034). In some embodiments, the system continues the wiring process as described elsewhere (9036).

[0271] In some embodiments, parameters sensed by one or more sensors at the extension, gimbal block, or other location in the system, such as forces, thresholds, and motion values ​​related to the wire and insertion process, are stored in a database.

[0272] Example of wire management held by two wiring arm modules In some embodiments, when a wire is held by two wiring arm modules, the system includes instructions for holding the wire in a specific manner. For example, the wire is held at a specific position relative to the electrical cabinet. In another example, the wire is held with constant tension between two points on the wire held by the two arms. In some embodiments, a set of instructions is prepared during the wiring design process and provided to each arm module. In some embodiments, this is done to allow the robotic arms to function without potentially causing damage to each other, without causing damage to the electrical cabinet, without causing damage to the wire, and / or without causing entanglement of the wire during the wiring process. In some embodiments, the tension on the wire is directional. For example, while one mechanical arm holds one end of the wire, the other mechanical arm holds the other end in the direction of the position allocated within the electrical cabinet (optionally above the duct / DIN), while maintaining tension.

[0273] In some embodiments, the function of holding and tensioning the wire is interchangeable between two mechanical arms. For example, at the start of the wiring action, the first mechanical arm holds the wire and does not move it, while the second mechanical arm slides the wire toward the position to which it will be allocated. When the second arm reaches the desired position on the electrical cabinet, it stops, and the first arm releases the wire and moves to the position where the second mechanical arm is positioned to continue the wiring process. At this point, the second mechanical arm holds the wire without moving it, while the first arm slides the wire toward the position within the electrical cabinet to which it will be located.

[0274] In some embodiments, during the wiring process, when laying wires on a duct / DIN, one of the two arms slides over the wire. For example, as described above when describing the case where the wiring end effector module 208 reduces the radial force on the wire, allowing the wire to slide while the mechanical arm moves (see Figures 7B1-7B5 and 9F).

[0275] In some embodiments, a distance is maintained between two wiring arms. In some embodiments, optionally, the distance is adjusted during cable placement relative to the cable route within a duct(s). In some embodiments, optionally, the distance between arms provides clearance from components located on the substrate. In some embodiments, if the tension exceeds a certain threshold, for example, 15% above a desired tension and / or a predetermined threshold, the movement of the arms slows down or stops. In some embodiments, the threshold is set according to the capabilities of the wiring arms, the type of wire, and any combination thereof. In some embodiments, the system monitors the distance between arms and maintains a constant distance between them. In some embodiments, if the distance between arms exceeds a certain predetermined distance, the movement of the arms is adjusted or stopped.

[0276] In some embodiments, if the system detects that the wire tension level and / or the distance between arms is outside tolerance and / or above or below a predetermined value, e.g., ±20% of a predetermined value / tolerance, the wiring end effector releases the wire to avoid potential damage to the arms and / or panels / components.

[0277] In some embodiments, a visual system is used to validate the process before placing the wires inside the duct.

[0278] In some embodiments, the operation of two wiring arms for cabinet wiring, such as (not an exhaustive list) the operation of one arm relative to the other, the operation of the arm relative to the cabinet, the operation of the arm relative to the wires, and the operation of the arm relative to the wiring diagram of the wires and wires in the panel, requires a high level of synchronization and precision during the operation of the arms at multiple levels.

[0279] In some embodiments, an example of dual-arm coordination during wire routing includes a first arm leading the routing process, meaning this arm inserts the end of the wire into the associated terminal connector within the component, and a second arm following and supporting the first arm during the routing process. In some embodiments, the leading routing arm can become the support arm during the routing process, and vice versa. In some embodiments, during the routing process, the support arm maintains a constant tension on the wire relative to the leading wire arm by maintaining a constant force on the wire (e.g., 2N, 4N, 8N). In some embodiments, during the routing process, the support arm maintains tension on a portion of the wire, for example, a portion of the wire held between two routing arms, while leaving the other portion untensioned (the wire slackens and / or hangs behind the wire end effector). In some embodiments, the length of the slack is about 10% to about 30% of the total length of the wire being routed. Optionally, it is about 5% to about 40% of the total length of the wire being routed. Optionally, approximately 1% to 50% of the total length of the wire being routed. For example, 15%, 20%, or 25% of the total length of the wire being routed. In some embodiments, during the routing process, the slack wire is held above the plane on which the panel components are located (see, for example, Figure 15, when routing is performed from above on a horizontally oriented panel) and / or at a distance from the plane on which the panel components are located (see, for example, Figure 3, when routing is performed from the side on a vertically oriented panel). In some embodiments, if the lead arm moves toward the insertion point and guides the wire along the path drawn on the panel, the second arm is kept at a constant distance behind the first arm. In some embodiments, as the leading arm moves toward the insertion point and guides the wire along the path drawn on the panel, the second arm is maintained in a position related to the next point where the wire needs to be inserted. For example, if the wire needs to be inserted through a hole in a duct, the first arm inserts the end of the wire into the hole, and the second arm further becomes a leading wiring arm by waiting on the opposite side of the hole and catching the end of the wire.In some embodiments, the position of the second arm is set relative to the duct path and wiring direction, as the wire may be routed within the duct or pass through a clip. In some embodiments, if the duct is straight, the second arm may be positioned at a duct position far from the component being wired. In some embodiments, the second arm is used to facilitate wire twisting, for example, to facilitate bending of the wire within a panel. In some embodiments, optionally, if bending of the duct path is anticipated, the second arm is positioned above this position to facilitate wire twisting. In some embodiments, while positioning the wire at a location where the wire direction changes, for example at a corner of the duct, an excess of wire is intentionally left after the point of change in wire direction and before positioning the wire. In some embodiments, a potential advantage of doing this before positioning the wire is to provide enough wire to allow the wire to be properly positioned without pulling the wire and / or causing distortion to the wire while changing direction at a required point in the path.

[0280] In some embodiments, the wiring process involves inserting the first end of a wire into a terminal connector of a component inside the cabinet, and then guiding the cable along a path drawn on a design drawing inside the cabinet, connecting the other end of the wire to a second terminal connector in the second component inside the cabinet. In some embodiments, for example, once the first end of the wire is inserted into the first component, a second arm becomes a leading arm, guiding the wire towards the second component, while the first arm becomes a support arm.

[0281] In some embodiments, the support arm performs one or more of the following actions: securing the wire within the duct (optionally using other tools, e.g., passive fingers, staplers, gluers, and / or latching elements; or may be used to position a plastic retaining strip ("bridge") to clear a path for the lead arm; or validating the routing process using one or more sensors (e.g., a camera, force sensor, laser line sensor, and / or proximity sensor)). In some embodiments, the safety zone is defined, for example, above component level (see, for example, Figure 15, when the wiring is run from above on a panel where it is positioned horizontally) and / or at a distance from the plane on which the panel components are located (see, for example, Figure 3, when the wiring is run from the side on a panel where it is positioned vertically), and the support arm with the wire operates within the safety zone. In some embodiments, the panel is divided into a plurality of local safety zones, optionally having different safety heights. In some embodiments, as described above, optionally, the wiring arm provides means for securing and / or attaching the wire to a specific location within the panel and / or duct by comprising a wire bonding element (e.g., adhesive, adhesive tape, staples) actuated by one or more dedicated devices. In some embodiments, as also described elsewhere in this specification, a support arm slides along the wire, positioning it in place along its path on the panel, while a leading arm guides the distal end of the wire to its next point in the panel.

[0282] In some embodiments, where multiple wires are located within the same duct, the position of the held and operated wire is relative to the already positioned wires; for example, if the center of the duct is occupied by other wires, the support arm positions the currently positioned wire to one side of the duct and / or brings it closer. In some embodiments, the software takes into account the load on the duct and optionally adds length to the wire to compensate for the additional distance required for the load on the wire within the duct, for example, by 1%, 2%, or 5%.

[0283] Examples of optimization features for automated routing processes In some embodiments, the system comprises one or more features configured to optimize the automated routing process performed by an exemplary horizontal / vertical automated routing system.

[0284] Cartridge for waste wires during the wiring process In some embodiments, as described above, while a leading wiring arm positions a wire along a path drawn in the design within the cabinet, a support wiring arm supports the actions performed by the leading wiring arm. In some embodiments, one of these support actions is to hold the rest of the wire being "dragged" while the leading wiring arm moves the end of the wire through the wiring path. In some embodiments, the wiring arms optionally include a dedicated cartridge into which excess wire is wound and / or held when a particular wire arm functions as a support wiring arm. In some embodiments, both arms optionally include a dedicated cartridge because the leading and support roles may change during the wiring process. In some embodiments, the wire held in the dedicated cartridge is released as needed during the wiring process, for example, if a lot of excess wire is needed for the movement of the arm, taking into account ducts and / or obstacles in the wiring path. In some embodiments, a potential advantage of having a dedicated cartridge is that by keeping long wires contained during the wiring process, it is possible to potentially avoid excess wire causing damage or entanglement during the wiring process.

[0285] Example of obstacle removal using a support wiring arm In some embodiments, during the wiring process, if a wire positioned within the cabinet by the lead wiring arm may become entangled and / or fail to be correctly positioned at the desired location along the path, the system is configured to activate a support wiring arm and take action to resolve these issues. For example, the support wiring arm moves an obstacle (e.g., another wire already positioned within the cabinet) away from the wire being positioned, using a dedicated tool (e.g., tweezers, elongated rod) that allows interaction with the other wires without damaging them, optionally. In some embodiments, the support wiring arm does not hold the wire being positioned while removing the obstacle. In some embodiments, the wire is routed around the obstacle with two arms, optionally. In some embodiments, instead, a new path is calculated to bypass the obstacle.

[0286] Use of one wiring arm (if possible) In some embodiments, the system is not required to use two wiring arms for the wiring process. In some embodiments, for example, when wiring short wires (e.g., having lengths of 1 cm, 2 cm, or 5 cm), the system is configured such that one wiring arm performs the entire wiring process, leaving the second arm to perform other tasks related to the overall wiring process of the cabinet. In some embodiments, optionally, for short wires, the wiring arm fixes one end of the wire within the object / component, then slides along the wire (possibly "sensing" the sliding motion) to the other end, and then inserts the other end into the required position. In some embodiments, optionally, after the initial insertion, the arm releases the wire and optionally, with the assistance of a sensor such as a vision camera, grasps the wire again at the other end.

[0287] Use of grip and slip during the wiring process In some embodiments, the system utilizes its "grip and slide" function to allocate wires along a path drawn on a design. For example, a wiring arm can hold a wire on the top of a surface where it needs to be positioned and then slowly move along the wire while positioning it within the desired path (the "slide" component of the "grip and slide" function).

[0288] Example of operation of a circuit breaker In some embodiments, the wire end effector is configured to activate a circuit breaker within a panel, for example, by moving it upward / downward and / or pushing it in. In some embodiments, the activation is performed using an extension. In some embodiments, the activation is performed using a dedicated actuator. In some embodiments, switching the component on / off performs specific tests, such as continuity tests, load tests, and logic tests (of circuit logic).

[0289] Use of complex wires In some embodiments, the system is configured to operate not only single-wire wires but also wires containing one or more splits within the wire to provide multi-wire wires and / or harnesses. In some embodiments, for example, a wire with a T-shaped harness having three ends, a support arm holds the position on the wire where the splits are provided, and a leading arm inserts one end of the wire into a component, and then inserts the second end of the wire into a second component.

[0290] Example of using the system on a wire harness inside a cabinet In some embodiments, the extension of the end effector is configured to hold a wire head that needs to be inserted into a component. For example, a network cable includes a dedicated wire head (known as an RJ45 connector). In this example, the extension of the end effector is configured to hold the RJ45 connector of the network cable and connect it to a dedicated component in the cabinet. In some embodiments, the system includes information on sensory feedback, such as force, torque, and visual feedback, that is recorded when these types of wire heads are connected. In some embodiments, sensory feedback is used to validate that the wire head is properly inserted into place. In some embodiments, after the wire head is inserted into place, the wire head is secured in place using a locking actuator, for example, by tightening a screw on the connector in the component. In some embodiments, a dual-push action (i.e., push, release, and re-grasp) is used to insert the wire head.

[0291] Selective splitting of tasks on the timeline In some embodiments, the system is configured to perform part of a task, stop, perform another task, and then select and finish the previous task. For example, connecting one end of a wire to a connector, positioning the wire along a path drawn on a design, releasing the wire, performing another task, and then returning to the previously left wire and continuing to position and / or connect it to the connector. In some embodiments, re-grabbing the wire is done using a visual system and / or by going to a known location (component, clip, corner) and sliding along the wire to its end.

[0292] An example of giving multiple degrees of freedom to a wire-end effector. In some embodiments, the wire end effector is given multiple degrees of freedom (DOF) to allow it to overcome obstacles and / or wire congestion. In some embodiments, the wire end effector or the arm in operation is given six degrees of freedom: three rotations and three translational movements around each vertical axis. In some embodiments, the wire end effector is given seven or more degrees of freedom. In some embodiments, a potential advantage of giving more than six degrees of freedom is that it may introduce redundancy (or excessive redundancy) issues in the software, but it may also allow for wire manipulation to resolve obstacles and / or position wires in congested situations.

[0293] Smart identification markers on components In some embodiments, components used within an electrical cabinet include a smart identification marker on its top so that the smart identification marker can be read by an automated wiring system during the wiring process. For example, a marker along a duct provides a reference point for the position of a wiring arm along the duct. For example, in this example, a particular connector called connector X is located at a specific coordinate within the electrical cabinet and includes a smart identification marker. In some embodiments, a mechanical arm is equipped with a reader or camera or sensor for the smart identification marker, which is used to confirm that the mechanical arm has arrived correctly in the correct position.

[0294] Position markers on electrical cabinets In some embodiments, the electrical cabinet is provided with dedicated position markers, which are added to the information stored in the design console 102 and used and identified by a mechanical arm during the wiring process, for example, using a camera or reader.

[0295] Use of self-locking components / connectors In some embodiments, the electrical panel is provided with components that do not include connectors, such as screws for locking wires in place, by using a self-locking mechanism.

[0296] Smart duct / DIN example In some embodiments, the electrical panel is provided with smart ducts or smart DIN rails (or both) configured to assist the automated wiring process. For example, the ducts may include one or more clips and / or holders and / or reversible connectors for wires, which, once positioned, hold the wires placed within them. In some embodiments, a potential advantage of this is that already placed wires do not interfere with the rest of the wiring process. In some embodiments, the ducts / DINs include one or more position markers, which are also stored in the design console 102 and used and identified by a mechanical arm. In some embodiments, the smart ducts / DINs are configured to accept smart wires as described below. In some embodiments, the electrical panel is configured to allow the wires to be covered by positioning the wires and then positioning the inverted duct on top of the positioned wires. In some embodiments, the ducts / DINs are positioned by a mechanical arm at an angle to assist the automated wiring. For example, they may be positioned at an angle of about 1 to 15 degrees relative to the electrical cabinet. In some embodiments, the duct / DIN includes a fastening strip configured to fasten wires to the duct / DIN when in place. In some embodiments, the duct has a side opening to provide easy access for a robot to place and / or route wires along the side. In some embodiments, the duct may have markings that potentially facilitate the alignment / positioning of the duct relative to the rest of the panel, for example, the markings may include a scale / color, etc. In some embodiments, the duct includes one or more attachments to allow a wire assembly robot to place wires before / during or after the wires are placed. For example, the duct may have adhesive at the bottom, which, once placed, can secure the duct to the panel.

[0297] In some embodiments, the DIN rail has markings at one or two ends to allow for precise positioning and identification of the position of the panel within the rail. In some embodiments, optionally, marking components are added to the end of each array of components mounted on the DIN rail to identify the end and / or start positions of the components placed on the DIN rail.

[0298] In some embodiments, the wire is positioned within a panel without a duct, and after some or all of the wire positioning is completed, the wire is closed within the closed duct by positioning an inverted duct (meaning having an opening at the bottom and being covered at the top) at the top of the wire.

[0299] Examples of smart wires In some embodiments, electrical panels are wired by smart wires configured to assist an automated wiring process. For example, the wires may include one or more clips and / or holders and / or mountable reversible connectors for the wires, which hold the wires in place once inserted into the duct / DIN. In some embodiments, a potential advantage of this is that already-placed wires do not interfere with the rest of the wiring process. In some embodiments, the wires may include one or more position markers, which are also stored in the design console 102 and used by a mechanical arm to identify them during the wiring process. In some embodiments, the wires may include a connecting material (e.g., adhesive) that holds the wires in place once they are positioned, and optionally, the adhesive on the wires can be cured after placement. In some embodiments, the wires have a rough surface to help an elongated member grasp the wires. In some embodiments, the wires have different cross-sections, e.g., a square cross-section, to support better placement of the wires within the duct.

[0300] Example of an electrical cabinet without ducts In some embodiments, the electrical cabinet may not include any ducts at all, for example, by providing smart wires that can be attached to one another, and these wires hold the wires in place.

[0301] Example of wiring method using wiring arm module 206 Referring here to Figure 10, a flowchart of an exemplary wiring method by the wiring arm module 206 according to several embodiments of the present invention is shown. In some embodiments, the system receives information regarding the wire to be used, the length of the wire, and the type of wire end to be used (1002). In some embodiments, the wire preparation module prepares the wire as disclosed herein (1004). In some embodiments, the first end of the wire is picked up by the wiring arm module (1006). In some embodiments, the first end of the wire is operated to a position within the electrical cabinet (1008). In some embodiments, the wiring arm module 206 inserts the first end of the wire into the terminal connector of the first component, locks the wire within the terminal block, and performs validation by, for example, slightly pulling back the wire rather than increasing force and "sensing" the slippage of the elongated extensions 910a-b (1010). In some embodiments, the second end of the wire is picked up by the wiring arm module (1012). In some embodiments, the second end of the wire is operated to a position within the electrical cabinet (1014). In some embodiments, the operation of the second end of the wire involves routing the wire from the position where the first end of the wire is inserted through the wire channel / track until the second end of the wire reaches that position. In some embodiments, two wire arm modules work together during the insertion of a wire through a channel / track, similar to how humans would work together while performing the same task. For example, when inserting a wire into an angled channel / track, one arm holds the wire in a specific position and the other arm positions the wire in / through the channel / track, or, for example, if the wire needs to be passed through an orifice, one arm holds the wire on one side of the orifice and passes the end of the wire through the orifice, and the other arm grasps the end of the wire from the other side of the orifice. It should be understood that the above examples are merely illustrative and do not limit the invention in any way.

[0302] In some embodiments, the wiring arm module 206 inserts the second end of the wire into the connector of the second component, locks the wire in the terminal block, and performs validation (1016). In some embodiments, the system then evaluates whether there are any other wires required for the job (1018). In some embodiments, if the answer is "yes", the method starts from the beginning. In some embodiments, if the answer is "no", the system generates a report and terminates the job (1020).

[0303] Examples of data flow and operations Referring here to Figure 11, schematic diagrams of exemplary data flow and operation of an automated wiring system according to several embodiments of the present invention are shown. In some embodiments, the user begins by virtually drawing a design for an electrical cabinet (1102). In some embodiments, the user runs a simulation using dedicated software (1104). In some embodiments, the design creation is optionally optimized taking into account the results of the simulation (1106). In some embodiments, further simulations are performed until the best design is achieved. In some embodiments, before proceeding, the system performs a final evaluation to determine whether the design creation stage is complete (1108). In some embodiments, if the answer is "no", the system returns to the design creation stage. In some embodiments, if the answer is "yes", the system creates an electrical circuit design adapted for sharing on other platforms, the system creates a mechanical drawing of an electrical panel adapted for sharing on other platforms, and the system creates a bill of materials (BOM) for the assembly of the electrical cabinet (1110).

[0304] In some embodiments, at this point the system generates a wire routing sequence based on the electrical circuit diagram and the mechanical drawing (1111). In some embodiments, as described elsewhere in this specification, the generation of the wire routing sequence includes a virtual generation of a series of possible sequences of wires being inserted into the electrical cabinet and an evaluation of any problems that may occur during the actual wiring of the electrical cabinet. In some embodiments, optionally, the system runs a simulation to optimize the wire routing sequence according to the determined parameters, optionally.

[0305] In some embodiments, the actions described above include continuous data exchange between the user's computer designing the electrical circuit and the server (1112). In some embodiments, once all assembly preparations are complete, the electrical cabinet is assembled within the automated electrical wiring unit / system 106 according to the final version of the design drawings (1114). In some embodiments, during assembly, the automated electrical wiring unit / system 106 communicates with the server for continuous performance monitoring (1116).

[0306] Examples of lighting wiring fixtures In some embodiments, the automated electrical wiring system is used for wiring lighting units. The following paragraphs disclose examples of the use of the automated wiring system. It should be understood that the following are merely examples of the use of the automated wiring system provided to enable those skilled in the art to understand the present invention, and are not limiting in any way. Referring here to Figure 12, a schematic diagram of automated electrical wiring for a light-emitting unit 1200 according to some embodiments of the present invention is shown. In some embodiments, the automated electrical wiring for the light-emitting unit 1200 comprises a base 1202 to which different components of the automated electrical wiring for the light-emitting unit 1200 are mounted. In some embodiments, the automated electrical wiring for the light-emitting unit 1200 comprises at least one robotic arm 1204 including a wire end effector 1206. In some embodiments, the automated electrical wiring for the light-emitting unit 1200 optionally comprises an additional robotic arm configured to assist the main robotic arm 1208. In some embodiments, the automated electrical wiring for the light-emitting unit 1200 optionally comprises a depth camera 1210 configured to monitor the wiring action of the system. Figure 12 also shows an exemplary lighting panel 1212 at the location where the wiring process is performed.

[0307] Referring here to Figures 13A-B, schematic diagrams of exemplary wire end effectors 1206 for automatic electrical wiring of a light-emitting unit 1200 according to several embodiments of the present invention are shown. In some embodiments, the automatic electrical wiring system is used, for example, in a light-emitting unit / appliance (see below). In some embodiments, the wire end effector 1206 comprises a mechanical wire feeder 1302 including a dedicated motor 1304 configured to feed the required wire 1306 to a gripper 1308. In some embodiments, as described above, the gripper 1308 comprises two (optionally finger-shaped) extensions 1310a-b configured to grip and hold the wire 1306. In some embodiments, each extension is connected to a force-applying mechanism 1312a-b, which is configured to perform the movement of the two extensions 1310a-b that actuate the gripping / holding action. In some embodiments, a dedicated motor 1314 is connected to the force-applying mechanism 1312a-b. In some embodiments, the wire end effector 1206 optionally includes an end wire cutter 1316 configured to remove insulation around the wire, exposing the wire core. In some embodiments, the wire end effector 1206 optionally includes a vacuum system (not shown) configured to pick up waste from the end wire cutter 1316 and transport it into a waste container 1318.

[0308] Referring here to Figure 14, a close schematic diagram of the gripper 1308 and extensions 1310a-b according to several embodiments of the present invention is shown. The same part numbers are used. In some embodiments, the gripper 1308 is provided with one or more sensors 1320 on the extensions 1310a-b configured to monitor the force applied by the gripper 1308. In some embodiments, as described above, the sensors are alternatively or additionally located within a gimbal block(s) 370 holding the extensions. In some embodiments, as schematically shown in Figure 14, the gripper 1308 is provided with three main directions (F in1 F in2 and Fin3 A force is applied to the wire (marked as F) and monitored. In some embodiments, these forces are used to insert the wire 1306 into the wire terminal 1322, as schematically shown on the left side of Figure 14. In some embodiments, these forces (F) are used to insert the wire 1306 into the wire terminal 1322. in1 F in2 and F in3 The force ranges from approximately 5N to approximately 15N, optionally from approximately 7N to approximately 20N, optionally from approximately 8N to approximately 25N, for example, approximately 8N, approximately 10N, and approximately 12N. In some embodiments, the resolution of any of the above forces is approximately 1N.

[0309] Example of a horizontal automatic wiring system with a dedicated wire preparation module. In some embodiments, the automatic wiring system is configured to be mounted on a horizontal platform. In the automatic wiring systems shown in Figures 1A-B, 3 and 4, the automatic wiring system is mounted on a vertical platform, as disclosed herein, along with a nearby wire preparation module to provide the necessary wires, enabling the connection of wires on an upright cabinet. In the automatic wiring system shown in Figure 12, the automatic wiring system is mounted on a horizontal platform, as enabled the connection of wires on an object on the platform, along with a wire feeder incorporated into a wire end effector 1206.

[0310] The following paragraphs disclose a variant of a horizontal automatic wiring system equipped with a dedicated wire preparation module.

[0311] Referring now to Figure 15, a schematic diagram is shown of an exemplary horizontal automatic wiring system with a dedicated wire preparation module according to several embodiments of the present invention. In some embodiments, the system is mounted on a horizontal platform 1502, with all necessary equipment located on its top. As described above, in some embodiments, the system comprises one or more wiring arm modules 1504 (two shown in Figure 15), both optionally comprising wiring end effector modules 1506 and wire preparation modules 1508 similar to those disclosed above, which are configured to provide (e.g.) connection-prepared wires 1510 for use in wiring panels 1512. In some embodiments, similar to the system disclosed in Figure 12, the system optionally comprises a depth camera 1514 configured to monitor the wiring action of the system. In some embodiments, the wiring method is the same as those disclosed elsewhere in this specification.

[0312] Referring here to Figure 16, a schematic diagram of another exemplary horizontal automatic wiring system with a dedicated wire preparation module according to several embodiments of the present invention is shown. In some embodiments, the system comprises two separate systems, one allocated near the other. In some embodiments, one system is a wire preparation system 1602, comprising two fully automated mechanical arms 1604 configured to prepare wires 1606 for insertion into device 1608. In some embodiments, the other system is an automatic wiring system comprising two other automated mechanical arms 1610. In some embodiments, the wire preparation system 1602 can pre-prepare a number of wires 1612 to be left near the automatic wiring system 1610. In some embodiments, as with other systems, this system optionally comprises a depth camera 1614 configured to monitor the wiring action of the system. In some embodiments, the wiring method is the same as disclosed elsewhere in this specification.

[0313] Referring here to Figure 17A, an isometric schematic view of another exemplary horizontal automatic wiring system 1700 with a dedicated wire preparation module according to several embodiments of the present invention is shown. In some embodiments, the system comprises a base 1702 on which all components of the automatic wiring system are installed, as will be further described below. In some embodiments, the base 1702 comprises dedicated slots for the allocation of electrical cabinets 1722 on which the wiring is performed. In some embodiments, the electrical cabinets are positioned horizontally, as shown in, for example, the top view of the exemplary horizontal automatic wiring system 1700 shown in Figure 17B, to allow access to DINs and connectors for the wiring process. In some embodiments, the exemplary horizontal automatic wiring system 1700 comprises a wire preparation system 1704, as also shown in, for example, Figure 17C, which comprises two fully automated mechanical arms 1706 mounted on two horizontal rails 1714 and configured to prepare wires 1708 for insertion into electrical cabinets 1722. In some embodiments, the wire preparation system 1704, as disclosed in Figures 4, 5A-B, comprises at least one crimper 1710, a cutter (not shown), and an optional laser engraver 1712 for marking the wires. In some embodiments, multiple wires are held within a device 1716 configured to move vertically to allow better access of the associated wires to a mechanical arm 1706.

[0314] In some embodiments, the exemplary horizontal automatic wiring system 1700 comprises two additional automated mechanical arms 1718, similar to the mechanical arms disclosed above. In some embodiments, a wire preparation system 1704 can optionally pre-prepare a number of wires to be left near the two automated mechanical arms 1718. In some embodiments, as with other systems, the system optionally comprises a depth camera configured to monitor the wiring action of the system. In some embodiments, the wiring method is the same as those disclosed elsewhere in this specification. In some embodiments, each of the two automated mechanical arms 1718 is mounted on a base 1724 configured to move horizontally on a base 1702. In some embodiments, the exemplary horizontal automatic wiring system 1700 comprises a drawer-type panel handling module 1720 that moves to insert and / or remove an electrical cabinet 1722 before and / or after wiring, as shown, for example, in Figure 17D.

[0315] Examples of optional installation of electrical elements within an electrical cabinet. In some embodiments, in addition to an automatic wiring system, the system of the present invention can be configured to install electrical components in an electrical cabinet before the automatic wiring process. In some embodiments, a potential advantage of doing so is that all preparations for the electrical cabinet are performed and monitored in the same location.

[0316] Example of a single-arm system In some embodiments, the system includes a single mechanical arm configured to perform all automated actions of the wiring process. For example, a ready-made wire, ready for wiring, is held at one end by the mechanical arm and wound at the other end onto a winch, which then releases the wire as needed. In some embodiments, the winch with the wire is mounted directly from the wire preparation module to the mechanical arm.

[0317] The various embodiments and aspects of the present invention described above and claimed in the following claims find experimental support in the following exemplary embodiments.

[0318] Exemplary Embodiments Herein, the following exemplary embodiments are referenced, which, together with the above description, illustrate some embodiments of the present invention in an indefinite manner.

[0319] Referring here to Figures 18A and 18B, schematic diagrams of wiring processes using two automated mechanical arms according to several embodiments of the present invention are shown.

[0320] Figure 18A shows a schematic diagram of two automated mechanical arms 1802 / 1804. In the following description, one automated mechanical arm will be referred to as arm 1 1802 and the other automated mechanical arm as arm 2 1804. Also shown in Figure 18A is a schematic diagram of an electrical panel 1806 that requires wiring. Figure 18B shows a schematic diagram of the electrical panel 1806 in more detail. The exemplary electrical panel 1806 comprises five ducts 1808-1 / 5. The exemplary electrical panel further comprises several components, and in this example of the present invention, components A and B require wires for connecting them.

[0321] Furthermore, Figure 18B includes reference points circled from 1 to 8 for the following explanation.

[0322] As described above, in the following example, a wire needs to be placed between component A and component B. For this example, the chosen path from component A to component B is determined to be the wire connected to component A, extending from reference point 1 to reference point 2, then to reference point 3, and finally into duct 1808-3. Next, the wire needs to bend in duct 1808-3 toward reference point 4 and extend into duct 1808-5. Next, the wire needs to bend in duct 1808-5 toward reference point 5. Next, the wire needs to bend in duct 1808-4 toward reference point 6. After that, the wire exits duct 1808-4 at reference point 7 and is inserted into component B, then to reference point 8.

[0323] The following table summarizes the actions of Arm 1 1802 and Arm 2 1804 when positioning the wire from reference point 1 to reference point 8. [Table 1]

[0324] Referring now to Figure 19, a graph illustrating exemplary phases of wire insertion into the electrical terminal connector of a component, as identified by sensors within the gripper, according to several embodiments of the present invention. In some embodiments, as further disclosed above, the system is configured to identify different phases of wire insertion into the electrical terminal connector of a component. The graph in Figure 19 shows the force sensed by sensors on the finger-like extensions 910a-b of the gripper 1308 with respect to the held wire. In some embodiments, the phases are as follows:

[0325] Phase A: Moving toward the electrical terminal connector of the component. In some embodiments, during this phase, the wire is held by the gripper 1308, which is moving toward the electrical terminal connector of the component. In some embodiments, initially, the same force is sensed as when the wire is not encountering any obstruction. In some embodiments, at some point the wire makes contact with the electrical terminal connector of the component, and the sensor begins to sense an increase in the sensed force. When a certain peak is reached, the system moves to the next phase. In some embodiments, the peak may depend on the type of wire and / or the type of electrical terminal connector, and may be set arbitrarily based on that. In some embodiments, the relationship between the type of wire, the type of connector of the component, and the "sensed" force is learned by the system and stored in a dedicated database. In some embodiments, an AI algorithm is used to generate these peak values ​​based on the learned data.

[0326] Phase B: Retracting from the electrical terminal connector of the component. In some embodiments, once a certain peak is reached, the gripper 1308 begins to retract, while still holding the wire, without actually pulling the wire. In some embodiments, as shown in the graph, the sensed force decreases significantly as the gripper releases its grip.

[0327] Phase C: The gripper retracts from the electrical terminal connector of the component while pulling the wire. In some embodiments, to evaluate the correct connection between the wire and the electrical terminal connector of the component, the gripper gently holds the wire while continuing to retract from the electrical terminal connector of the component. In some embodiments, at this point, two things may happen: 1. The wire is correctly connected and there is no motion that would cause the gripper to slip on the connected wire, or 2. The wire is not correctly connected and is pulled out of the electrical terminal connector. In some embodiments, as described above, after each trial, the value is learned and / or adjusted.

[0328] In some embodiments, different types of electrical terminal connectors and different types of wires are characterized by different forces, which are sensed by the gripper. In some embodiments, the system includes a database in which different combinations of different types of electrical terminal connectors and different types of wires are stored, and the system acts the gripper accordingly according to input provided by the user.

[0329] Referring now to Figures 20A-C, three different examples of forces sensed by the gripper in three different scenarios according to several embodiments of the present invention are shown. Figure 20A shows an example of what the sensor senses while the gripper is retracting, and the wire is not connected at all to the electrical terminal connector of the component. In this case, the sensed force does not increase because the wire does not resist the pull of the gripper.

[0330] Figure 20B shows an example of what the sensor sensed while the gripper was retracting, where the wire was not properly connected to the electrical terminal connector of the component. In this case, the gripper initially begins to retract until the wire resists the pull, which translates to an increase in the sensed force. At some point, because the wire is not properly connected, it becomes detached from the electrical terminal connector of the component, which is evidenced by a sudden decrease in the sensed force, after which it returns to the same level as before.

[0331] Figure 20C shows an example of what the sensor senses during the retraction of a gripper, with the wire correctly connected to the electrical terminal connector of the component. In this case, the gripper initially begins to retract until the wire resists the pull, which translates into an increase in the sensed force. At some point, because the wire is properly connected, the gripper begins to slip on the wire, which is evidenced by the decrease in the sensed force on the gripper at the end of the graph.

[0332] Referring here to Figure 21, several test experiments illustrating the characteristics of exemplary scenarios according to several embodiments of the present invention are shown. As previously disclosed, initially there is no resistance from the wire and the gripper moves, so the input from the force sensor is stable. Next, as the wire enters the electrical terminal connector of the component, the resistance between the wire and the connector causes a spike in the input from the sensor. Next, the device begins to pull the wire backward to evaluate the connection between the wire and the electrical terminal connector of the component. This part is characterized by a sudden decrease in the input received from the sensor, as shown in Figure 21. Then, depending on the outcome of the connection between the wire and the electrical terminal connector, various inputs are received from the sensor. In Test 1, as can be seen from the graph of no change, the wire came out of the connector. In Test 2, the wire broke off from the connector while the wire was being pulled backward. In Test 3, the wire was fully connected to the connector and the gripper slipped on the wire during the backward pull. In Test 4, the wire broke off from the connector while the wire was being pulled backward. The graphs described above are exemplary experiments provided to enable those skilled in the art to understand the present invention and are not limiting in any way.

[0333] When used herein in relation to quantity or value, the term “about” means “within ±20% of that value.”

[0334] The terms "comprises," "comprising," "includes," "including," "has," and "having," as well as their cognates, all mean "including but not limited to."

[0335] The phrase "consisting of" means "including and limited to."

[0336] The phrase "consisting essentially of" means that a composition, method, or structure may include additional components, steps, and / or parts, provided that these additional components, steps, and / or parts do not substantially alter the basic and novel properties of the claimed composition, method, or structure.

[0337] As used herein, unless the context clearly indicates otherwise, the singular forms “a,” “an,” and “the” refer to multiple objects. For example, the terms “a compound” or “at least one compound” may refer to multiple compounds, including mixtures thereof.

[0338] Throughout this application, embodiments of the present invention may be presented by reference to range forms. It should be understood that descriptions in range form are merely for convenience and brevity and should not be interpreted as inflexible limitations on the scope of the present invention. Therefore, range descriptions should be considered to specifically disclose not only the individual numerical values ​​within that range, but also all possible subranges. For example, a range description such as "1-6" should be considered to specifically disclose subranges such as "1-3," "1-4," "1-5," "2-4," "2-6," and "3-6," as well as the individual numerical values ​​within those ranges, e.g., 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

[0339] Where a range of numbers is indicated herein (for example, "10 to 15", "10 to 15", or a set of numbers linked by such other range indications), unless the context clearly indicates otherwise, it means that the range includes any number (fraction or integer) within the indicated range limit, including the range limit. The phrases "range / ranging / ranges between" between the first and second indicated numbers, and "range / ranging / ranges from" between the first and second indicated numbers, "to", "up to", "until", or "through", are used interchangeably herein and mean that the range includes the first and second indicated numbers and all fractional and integer digits between them.

[0340] Unless otherwise indicated, the numerical values ​​used herein and any numerical ranges derived therefrom are approximations within reasonable measurement accuracy and rounding tolerances as understood by those skilled in the art.

[0341] For clarity, it is understood that certain features of the present invention described in the context of separate embodiments may also be provided in combination in a single embodiment. Conversely, for brevity, various features of the present invention described in the context of a single embodiment may also be provided separately, in any preferred secondary combination, or as suitable for any other described embodiment of the present invention. Certain features described in the context of various embodiments should not be considered essential features of those embodiments unless the embodiments would not function without those elements.

[0342] Although the present invention has been described in relation to its specific embodiments, it is obvious that many alternatives, modifications, and variations will be apparent to those skilled in the art. Therefore, it is intended to encompass all such alternatives, modifications, and variations that fall within the spirit and broad scope of the appended claims.

[0343] All publications, patents, and patent applications described herein are incorporated herein by reference in their entirety, as if explicitly and individually noted, where each individual publication, patent, or patent application is indicated to be incorporated herein by reference. Furthermore, any citation or specification of any reference in this application should not be construed as an acknowledgment that such reference is available as prior art of the present invention. Where section headings are used, they should not necessarily be construed as restrictive. Furthermore, any priority document(s) of this application are incorporated herein by reference in their entirety.

Claims

1. An automated electrical wiring system for connectors that require electrical wiring, a. At least one wiring arm module, wherein the wiring arm module is provided with a wiring end effector at the distal end of the at least one wiring arm module for holding and manipulating wires, b. At least one sensor configured to detect at least one property related to the holding and manipulation of the wire, c. A circuit, i. By using the at least one wiring arm module equipped with the wiring end effector, a command for performing electrical wiring activity is received, ii. Adjust the operation of the at least one wiring arm module and the wiring end effector, taking into account the detected properties from the at least one property related to the holding and operation of the wire, which are detected by the at least one sensor and caused by the activity. Includes a circuit The aforementioned wiring end effector is configured to hold the end of the wire, The circuit further, iii. Inserting the end of the wire into the connector that requires electrical wiring, iv. Determining the correct insertion and locking of the end of the wire into the connector by evaluating the resistance to pulling the wire out of the connector, as detected by at least one of the sensors, It is configured to do the following: The detection of at least one property related to the holding and manipulation of the wire includes measuring axial force and radial force. Automatic electrical wiring system.

2. The automatic electrical wiring system according to claim 1, wherein the at least one property is one or more of the state of the wire, the deformation of the wire, the position of the wire, the force applied to the wire, the torque applied to the wire, and the type of connector.

3. The automatic electrical wiring system according to claim 1, wherein the wiring end effector includes a wire holding element.

4. The wire holding element comprises a wire clamping element including two extensions, and the two extensions are a. Two elongated extensions, b. Connected by an electrical mechanism, and, c. Connected by a pneumatic mechanism, One or more of the following: The automatic electrical wiring system according to claim 1.

5. The detection of at least one property related to the holding and operation of the wire is performed in three main directions (F) related to the wiring end effector. in1 , F in2 , F in3 The automatic electrical wiring system according to claim 1, comprising monitoring the force in ).

6. The wire holding element is a. A mechanism for movement along the socket axis of the connector, b. One or more sensors for monitoring the force applied by the wire clamping element, The automatic electrical wiring system according to claim 4, comprising one or more of the following:

7. The aforementioned wiring end effector is, a. One or more sensors for monitoring the force applied to the wire holding element, b. A wire lock element, wherein the wire lock element is i. One or more mechanisms for moving the wire lock element in one or more directions in order to interact with the locking mechanism within the connector, ii. One or more sensors for monitoring the locking operation of the wire lock element on the locking mechanism within the connector, wherein the wire lock element is configured to operate the locking mechanism within the connector according to predetermined measurement parameters monitored by the one or more sensors, A wire lock element comprising one or more of the following: The automatic electrical wiring system according to claim 4, comprising one or more of the above.

8. The circuit receives the command for performing electrical wiring activities from at least one design console, a. The at least one design console is one or more of the following: electronic devices, computers, tablets, mobile phones, and servers. b. The at least one design console includes dedicated software for creating electrical circuit design diagrams, c. The at least one design console communicates with at least one server, d. The at least one design console includes dedicated software for creating mechanical drawings, e. The at least one design console includes dedicated software for generating mergers of electrical circuit diagrams and mechanical drawings, f. The at least one design console includes dedicated software for generating wire routing sequences according to one or more of the electrical circuit design drawings and mechanical drawings, The automatic electrical wiring system according to claim 1, wherein at least one of the following is true.

9. The automatic electrical wiring system according to claim 1, further comprising a monitoring system.

10. The aforementioned monitoring system a. One or more cameras, b. One or more sensors, c. One or more torque sensors, d. One or more current sensors, The automatic electrical wiring system according to claim 9, comprising one or more of the following:

11. The automatic electrical wiring system according to claim 9, wherein the monitoring system includes one or more force sensors.

12. The automatic electrical wiring system according to claim 1, wherein the at least one wiring arm module includes a plurality of joints.

13. The at least one wiring arm module is, a. Can it be attached to a rail? b. It is configured to be accessible from the side to the connector that requires electrical wiring, c. It is configured to approach the connector requiring electrical wiring from above, and, d. The terminal wire port is configured to approach the connector that requires electrical wiring along the angle of the terminal wire port, One or more of the following: The automatic electrical wiring system according to claim 1.

14. The two wiring arm modules cooperate with each other in the operation of the wire, a. During the operation, the two wiring arm modules are separated from each other so as to apply tension to the wire, b. No tension is applied to the portion of the wire that is not held between the two wiring arm modules. c. During the operation, one of the two wiring arm modules grips the wire, and the other wiring arm module slides along the wire to a desired position. d. The portion of the wire held without tension is approximately 1% to approximately 50% of the total length of the wire. e. The system is configured to monitor the movement of each of the two wiring arm modules, f. The motion is one or more of the following: the motion of the other of the two wiring arm modules relative to one of the two wiring arm modules, the motion of each of the two wiring arm modules relative to the connector, the distance between the two wiring arm modules, and the tension of the wire held between the two wiring arm modules. g. The system is configured to correct the motion when a predetermined value is detected with respect to the motion, The automatic electrical wiring system according to claim 1, wherein at least one of the following is true.

15. The automated electrical wiring system according to claim 1, further comprising a wire preparation module configured to prepare wires to be inserted into connectors requiring electrical wiring, the wire preparation module providing the wires ready for use to the at least one wiring arm module.

16. The automatic electrical wiring system according to claim 1, further comprising the connector that requires electrical wiring.

17. The connector is configured to be connected inside an electrical cabinet. The electrical cabinet includes one or more smart components configured to support the electrical wiring, The automatic electrical wiring system according to claim 16, wherein the one or more smart components are one or more of a smart wire, a smart duct, a latch, a holder, and a marker.

18. A method for automatically connecting at least one wire to at least one connector, a. Automatically gripping the distal end of at least one wire with at least one wire holder, b. Automatically moving the at least one wire holder to bring the distal end of the at least one wire closer to the at least one connector, c. Automatically inserting the distal end of the at least one wire into the at least one connector, d. Automatically evaluate whether the at least one wire is properly connected to the at least one connector, Includes, The method further includes detecting at least one property of the at least one wire associated with the at least one connector during the automatic insertion and the automatic evaluation, A method for detecting at least one property of at least one wire associated with the at least one connector, comprising measuring an axial force and a radial force.

19. The method according to claim 18, wherein the at least one property is one or more of the state of the at least one wire, the deformation of the at least one wire, the position of the at least one wire, the force applied to the at least one wire, and the torque applied to the at least one wire.

20. The method according to claim 18, wherein the insertion is performed by moving one or more of the at least one wire holder and the robot arm to which the at least one wire holder is attached.

21. The method according to claim 18, wherein the detection includes detecting a force applied to the at least one wire when it is in contact with the at least one connector.

22. The two wiring arm modules cooperate with each other when making the connection of at least one wire, and the method further includes monitoring the movement of each of the two wiring arm modules. The motion is one or more of the following: the motion of the other of the two wiring arm modules relative to one of the two wiring arm modules; the motion of each of the two wiring arm modules relative to the connector; the distance between the two wiring arm modules; and the tension of the wire held between the two wiring arm modules. The method according to claim 18, further comprising correcting the motion when a predetermined value is detected with respect to the motion.

23. The detection of at least one property of the at least one wire associated with the at least one connector is based on three main directions (F) associated with the wiring end effector. in1 , F in2 , F in3 The method according to claim 18, comprising monitoring the force in ).

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