Interchangeable tools for automated robotic wiring systems

Abstract

The end effector is an end effector of a robotic wiring system and includes a wire holder having a first type of interchangeable tool, the wire holder including a first adapter configured to allow replacement of the first type of interchangeable tool.

Description

[Technical Field]

[0001] [Related Applications] This application claims priority to U.S. Provisional Patent Application No. 63 / 447,076, filed February 21, 2023, the contents of which are incorporated herein by reference in their entirety.

[0002] The present invention, in some embodiments thereof, relates to interchangeable tools for robots, particularly but not exclusively to interchangeable tools for robots in wiring systems. [Background technology]

[0003] Furthermore, as background art, U.S. Patent No. 10,099,371 discloses a robot that can dynamically change end effectors and loads and executes software that operates the end effectors without modifying the main control program. When a corresponding end effector is detected, the driver is dynamically linked and executed during program execution. Typically, the robot controller maintains a library of drivers and loads the appropriate driver when a new end effector is detected.

[0004] U.S. Patent Application Publication No. 20190054634 discloses an effector unit that can be locked and unlocked by relative movement of a robot, allowing multiple effectors to be used with the effector unit, and a corresponding method for automatically changing the effectors.

[0005] U.S. Patent Application Publication No. 20220193925 discloses a tool exchange system for an industrial robot, the system including: a base member for holding a tool and for arranging an operating device of the industrial robot; a tool storage unit for holding the tool when released from the base member; a base member force application device for applying a force to the tool toward the base member in any orientation of the base member when the tool is held on the base member; and a tool storage unit force application device for applying a force to the tool toward the tool storage unit in any orientation of the tool storage unit when the tool is held in the tool storage unit. A method for handling tools by an industrial robot is also disclosed. Summary of the Invention

[0006] Below is a non-exhaustive list including some example embodiments of the present invention. The present invention also includes embodiments including fewer than all features of an example, and embodiments that use features from more than one example, even if not explicitly listed below.

[0007] Example 1. A wire holder with a first type of interchangeable tool is provided. End effector of a robotic wiring system.

[0008] Example 2. The wire holder includes a first adapter configured to allow exchange of the first type of exchangeable tool. The end effector described in Example 1.

[0009] Example 3. The first type of interchangeable tool is one or more of a wire gripping tool, a USB gripper, an RJ45 gripper, an HDMI® gripper, a continuity test probe, and a USB data transfer tool. 3. The end effector of example 1 or 2.

[0010] Example 4. The first type of interchangeable tool comprises two elongated finger-like extensions. The end effector according to any one of Examples 1 to 3.

[0011] Example 5. The two elongated finger extensions are driven using a "scissor-like" mechanism. The end effector according to any one of Examples 1 to 4.

[0012] Example 6. The "scissor" mechanism provides angular motion to the two elongated finger-like extensions. The end effector according to any one of Examples 1 to 5.

[0013] Example 7. The two elongated finger-like extensions are characterized by one or more actuation states including an open state, a semi-closed state, and a closed state. The end effector according to any one of Examples 1 to 6.

[0014] Example 8. The wire holder includes a caging actuator configured to maintain the first type of interchangeable tool in an actuated state during use of the end effector. The end effector according to any one of Examples 1 to 7.

[0015] Example 9. The two elongated finger-like extensions are characterized in that the distance between the two elongated finger-like extensions is about 2 mm to about 7 mm. The end effector according to any one of Examples 1 to 8.

[0016] Example 10. The two elongated finger-like extensions are configured such that the distance between the two elongated finger-like extensions is such that the required object is held. The end effector according to any one of Examples 1 to 9.

[0017] Example 11. The two elongated finger-like extensions are configured to apply a force of about 1 N to about 20 N. The end effector according to any one of Examples 1 to 10.

[0018] Example 12. The two elongated finger extensions are configured to grip wires having a diameter of about 0.5 mm to about 6.0 mm and larger diameter wires. The end effector according to any one of Examples 1 to 11.

[0019] Example 13. Each of the two elongated finger-like extensions comprises a distal end configured to hold one or more of a wire, a connector, a USB connector, an RJ45 connector, an HDMI connector, a cable, a tube, a fiber optic cable, and a fiber optic tube. The end effector according to any one of Examples 1 to 12.

[0020] Example 14. The wire holder comprises one or more first sensors configured to monitor an action performed by the wire holder. The end effector according to any one of Examples 1 to 13.

[0021] Example 15. One of the one or more first sensors is at least one force sensor that measures force from one or more axes. The end effector according to any one of Examples 1 to 14.

[0022] Example 16. The end effector includes dedicated calibration information used by the one or more first sensors for each type of the first type of exchangeable tool. The end effector according to any one of Examples 1 to 15.

[0023] Example 16a. At least one sensor of the one or more first sensors is positioned on the end effector and is additionally configured to monitor the first type of interchangeable tool. The end effector according to any one of Examples 1 to 16.

[0024] Example 17. One or more of the one or more first sensors are positioned on the first type of exchangeable tool. The end effector of any one of Examples 1 to 16a.

[0025] Example 18. The wire holder comprises one or more first motors for moving the wire holder in one or more directions. The end effector according to any one of Examples 1 to 17.

[0026] Example 19. The wire holder includes one or more second sensors for monitoring movement of the wire holder. The end effector according to any one of Examples 1 to 18.

[0027] Example 20. One of the one or more second sensors is at least one anti-collision sensor for monitoring external forces applied to one or more parts of the end effector during use. The end effector according to any one of Examples 1 to 19.

[0028] Example 21. The wire holder includes an exchangeable tool locking portion for locking the first type of exchangeable tool in place. The end effector according to any one of Examples 1 to 20.

[0029] Example 22. The first type of interchangeable tool comprises at least one identification mark. The end effector according to any one of Examples 1 to 21.

[0030] Example 23. The first type of interchangeable tool has a distal end that holds a component at an angle relative to the axis of the first type of interchangeable tool. The end effector according to any one of Examples 1 to 22.

[0031] Example 24: The angle is in the range of about 0° to about 180°. The end effector according to any one of Examples 1 to 23.

[0032] Example 25. The distance from the distal end of the first type of exchangeable tool to the first adapter is about 10 mm to about 300 mm. The end effector according to any one of Examples 1 to 24.

[0033] Example 26. The first type of interchangeable tool has a total width of about 1 mm to about 10 mm. The end effector according to any one of Examples 1 to 25.

[0034] Example 27: The end effector replaces the first type of exchangeable tool from a plurality of the first type of exchangeable tools arranged in a dedicated stand for the first type of exchangeable tool. The end effector according to any one of Examples 1 to 26.

[0035] Example 28. Further comprising a wire lock with a second type of replaceable tool. The end effector according to any one of Examples 1 to 27.

[0036] Example 29. The second type of interchangeable tool is a power screwdriver configured to accept one or more interchangeable driver bits. The robot wiring system according to any one of Examples 1 to 28.

[0037] Example 30. The power screwdriver includes a second adapter configured to allow replacement of the one or more interchangeable driver bits. The end effector according to any one of Examples 1 to 29.

[0038] Example 31. The second type of replaceable tool is a motorized pressing tool configured to press a locking mechanism in an electrical connector terminal. The end effector according to any one of Examples 1 to 30.

[0039] Example 32. The wire locking portion includes one or more third sensors that monitor the locking operation of the wire locking portion. The end effector according to any one of Examples 1 to 31.

[0040] Example 33. One of the one or more third sensors is a torque sensor configured to monitor torque on a locking mechanism of the electrical terminal connector. The end effector according to any one of Examples 1 to 32.

[0041] Example 34. The wire locking portion includes one or more second motors for moving the wire locking portion in one or more directions. The end effector according to any one of Examples 1 to 33.

[0042] Example 35. The first type of interchangeable tool is configured to perform operations related to an automated wiring process. The end effector according to any one of Examples 1 to 34.

[0043] Example 36. The second type of interchangeable tool is configured to perform operations related to an automated wiring process. The end effector according to any one of Examples 1 to 35.

[0044] Example 37. The operation is one or more of gripping a wire, gripping a tube, gripping a cable, locking a wire, testing continuity, and transmitting data. The end effector according to any one of Examples 1 to 36.

[0045] Example 38. The first type of interchangeable tool is configured to fit into a narrow space. The end effector according to any one of Examples 1 to 37.

[0046] Example 39. The second type of interchangeable tool is configured to fit into a narrow space. The end effector according to any one of Examples 1 to 38.

[0047] Example 40. The first type of interchangeable tool is configured to be used in a verification process. The end effector according to any one of Examples 1 to 39.

[0048] Example 41. The second type of interchangeable tool is configured to be used in a verification process. The end effector according to any one of Examples 1 to 40.

[0049] Example 42. The first type of interchangeable tool is configured for use in a quality assurance (QA) process. The end effector according to any one of Examples 1 to 41.

[0050] Example 43. The second type of interchangeable tool is configured for use in a quality assurance (QA) process. The end effector according to any one of Examples 1 to 42.

[0051] Example 44. A single multi-sensor configured to monitor the process of all parts of the end effector. The end effector according to any one of Examples 1 to 43.

[0052] Example 45. The calibration information is generated by one or more of testing, analysis, and simulation. The end effector according to any one of Examples 1 to 44.

[0053] Example 46. a. At least one robotic arm comprising an end effector according to any one of Examples 1; b. a tool rest with a plurality of tools; A robot wiring system comprising:

[0054] Example 47. A method for performing a wiring process by an automatic wiring machine, comprising: a. receiving wiring information data including a plurality of operations; b. Picking up a dedicated tool for each of the plurality of tasks by the automatic wiring machine in accordance with the wiring information data; c. performing the work among the plurality of works in accordance with the wiring information data; the method including exchanging tools when a particular task among the plurality of tasks requires a tool different from the picked-up tool. method.

[0055] Unless otherwise defined, all technical and / or scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used to practice or test embodiments of the present invention, exemplary methods and / or materials are described below. In case of conflict, the patent specification, including definitions, will control. Furthermore, the materials, methods, and examples are illustrative only and are not intended to be necessarily limiting.

[0056] As will be appreciated by those skilled in the art, some embodiments of the present invention may be embodied as a system, method, or computer program product. Accordingly, some embodiments of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, microcode, etc.), or an embodiment combining software and hardware aspects, generally referred to herein as a "circuit," "module," or "system." Furthermore, some embodiments of the present invention may take the form of a computer program product embodied in one or more computer-readable medium(s) having computer-readable program code embodied therein. Implementation of the methods and / or systems of some embodiments of the present invention may involve performing and / or accomplishing selected tasks manually, automatically, or a combination thereof. Furthermore, depending on the actual instrumentation and implementation of some embodiments of the methods and / or systems of the present invention, some selected tasks may be performed by hardware, software, or firmware, and / or a combination thereof, for example, using an operating system.

[0057] For example, hardware for performing selected operations according to some embodiments of the present invention may be implemented as a chip or circuit. As software, selected operations according to some embodiments of the present invention may be implemented as a plurality of software instructions executed by a computer using any suitable operating system. In exemplary embodiments of the present invention, one or more operations according to some exemplary embodiments of the methods and / or systems described herein are performed by a data processor, such as a computing platform for executing a plurality of instructions. Optionally, the data processor includes volatile memory for storing instructions and / or data, and / or non-volatile storage, e.g., a magnetic hard disk and / or removable media, for storing instructions and / or data. Optionally, a network connection is also provided. Optionally, a display and / or a user input device, such as a keyboard or mouse, are also provided.

[0058] Some embodiments of the present invention may utilize any combination of one or more computer-readable medium(s). The computer-readable medium may be a computer-readable signal medium or a computer-readable storage medium. The computer-readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples of computer-readable storage media would include an electrical connection having one or more communication lines, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM) or flash memory, an optical fiber, a compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer-readable storage medium may be any tangible medium that can contain or store a program for use by or in connection with an instruction execution system, apparatus, or device.

[0059] A computer-readable signal medium may include a propagated data signal in which computer-readable program code is embodied, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including but not limited to, electromagnetic, optical, or any combination thereof. A computer-readable signal medium is not a computer-readable storage medium but may be any computer-readable medium that can communicate, propagate, or carry a program for use by or in connection with an instruction execution system, apparatus, or device.

[0060] The program code embodied on the computer readable medium and / or data used thereby may be transmitted using any suitable medium, including but not limited to wireless, wired, fiber optic cable, RF, etc., or any suitable combination of the above.

[0061] Computer program code for carrying out operations for some embodiments of the present invention may be written in any combination of one or more programming languages, including object-oriented programming languages ​​such as, for example, Java, Smalltalk, C++, and conventional procedural programming languages ​​such as, for example, the "C" programming language or similar programming languages. The program code may run entirely on the user's computer, partially on the user's computer as a standalone software package, 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 may 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 may be connected to an external computer (e.g., via the Internet using an Internet Service Provider).

[0062] Some embodiments of the present invention are described below with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. Each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, or other programmable data processing apparatus to create a machine such that the instructions, executed by the processor of the computer or other programmable data processing apparatus, create means for performing the function / acts specified in the block or blocks of the flowchart illustrations and / or block diagrams.

[0063] These computer program instructions may also be stored on a computer-readable medium that can instruct a computer, other programmable data processing apparatus, or other device to function in a particular manner, whereby the instructions stored on the computer-readable medium produce an article of manufacture that includes instructions that implement the functions / acts specified in the flowcharts and / or block diagrams of a block or blocks.

[0064] The computer program instructions may be loaded onto a computer, other programmable data processing apparatus, or other device to create a computer-implemented process such that the instructions executing on the computer or other programmable apparatus cause a series of operational steps to be executed by the computer, other programmable apparatus, or other device to provide a process for performing the functions / acts specified in the flowcharts and / or block diagrams of a block or blocks.

[0065] Some of the methods described herein are generally designed for use by a computer only and may not be suitable or practical for a human expert to perform entirely manually. A human expert wishing to manually perform a similar task, such as modifying a tool used in a wiring operation, would be expected to use an entirely different method, e.g., one that utilizes specialized knowledge and / or the pattern recognition capabilities of the human brain, which would be much more efficient than performing the steps of the methods described herein manually.

[0066] Some embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings. Specific reference will now be made in detail to the drawings, it being emphasized that the details shown are for the purpose of illustrating and discussing embodiments of the invention by way of example. In this regard, the description using the drawings will make apparent to those skilled in the art how embodiments of the invention may be practiced. [Brief explanation of the drawings]

[0067] [Figure 1] FIG. 1 is a schematic diagram of an exemplary automatic wiring system, according to some embodiments of the present invention. [Figure 2] FIG. 1 is a schematic diagram of an exemplary automatic wiring unit / automatic wiring system, according to some embodiments of the present invention. [Figure 3] FIG. 1 illustrates an example of a vertical automatic routing system according to some embodiments of the present invention. [Figure 4] FIG. 1 is a schematic diagram of a horizontal automated wiring system with a dedicated wire preparation module, according to some embodiments of the present invention. [Figure 5A] 1 is a schematic diagram of a multi-articulated wiring arm module according to some embodiments of the present invention. [Figure 5B] FIG. 1 is a schematic diagram showing a person performing a wiring operation. [Figure 5C] FIG. 1 is a schematic diagram showing a person performing a wiring operation. [Figure 5D] FIG. 1 is a schematic diagram showing a person performing a wiring operation. [Figure 5E] FIG. 1 is a schematic diagram showing a person performing a wiring operation. [Figure 5F] FIG. 1 is a schematic diagram showing a person performing a wiring operation. [Figure 6A] 1 is a schematic diagram illustrating a wiring arm module according to some embodiments of the present invention. [Figure 6B] 1 is a schematic diagram illustrating a wiring arm module according to some embodiments of the present invention. [Figure 7A] 1A-1C are schematic diagrams illustrating wired end effector modules according to some embodiments of the present invention. [Figure 7B] 1A-1C are schematic diagrams illustrating components of a wire retention element / wire holder according to some embodiments of the present invention. [Figure 7C] 1A-1C are schematic diagrams illustrating sensors on elongated extensions according to some embodiments of the present invention. [Figure 7D] 1A and 1B are schematic diagrams illustrating gimbal blocks with extensions connected thereto according to some embodiments of the present invention. [Figure 7E] 1A-1C are schematic diagrams illustrating exemplary movements of the gimbal blocks and an exemplary embodiment of a device having two gimbal blocks. [Figure 7F] FIG. 7 is a schematic diagram illustrating a wire locking element / wire lock 704 according to some embodiments of the present invention. [Figure 7G] 1A-1C are schematic diagrams illustrating several possible interactions that a wiring end effector module of some embodiments of the present invention can have with different types of terminal blocks having different locking mechanisms for wires within component connectors. [Figure 7H] FIG. 1 is a schematic diagram illustrating an exemplary ferrule according to some embodiments of the present invention. [Figure 7I] FIG. 1 is a schematic diagram illustrating an exemplary ferrule according to some embodiments of the present invention. [Figure 8] 1A and 1B are schematic diagrams illustrating wire end effector modules compatible with interchangeable tools according to some embodiments of the present invention. [Figure 9A] 1A-1C are schematic diagrams illustrating exemplary locking mechanisms for exchangeable tools according to some embodiments of the present invention. [Figure 9B] 1A-1C are schematic diagrams illustrating exemplary locking mechanisms for exchangeable tools according to some embodiments of the present invention. [Figure 9C] 1A-1C are schematic diagrams illustrating exemplary features of exchangeable tools according to some embodiments of the present invention. [Figure 9D] 1A-1C are schematic diagrams illustrating exemplary features of exchangeable tools according to some embodiments of the present invention. [Figure 9E] 1A-1C are schematic diagrams illustrating exemplary features of exchangeable tools according to some embodiments of the present invention. [Figure 10A] 1A-1C are schematic diagrams illustrating exemplary wire gripping mechanisms according to some embodiments of the present invention. [Figure 10B] 1A-1C are schematic diagrams illustrating exemplary wire gripping mechanisms according to some embodiments of the present invention. [Figure 10C] 1A-1C are schematic diagrams illustrating exemplary wire gripping mechanisms according to some embodiments of the present invention. [Figure 10D]1A-1C are schematic diagrams illustrating exemplary wire gripping mechanisms according to some embodiments of the present invention. [Figure 11] 1 is a schematic diagram illustrating a stand with multiple interchangeable tools according to some embodiments of the present invention. [Figure 12A] 1A-1C illustrate stands for different interchangeable tools according to some embodiments of the present invention. [Figure 12B] 1A-1C illustrate stands for different interchangeable tools according to some embodiments of the present invention. [Figure 12C] 1A-1C are schematic diagrams illustrating several exemplary replaceable wire gripping tools according to some embodiments of the present invention. [Figure 12D] 1A-1C are schematic diagrams illustrating a number of exemplary interchangeable tools configured to grip technical cables in accordance with some embodiments of the present invention. [Figure 12E] FIG. 1 is a schematic diagram illustrating several exemplary technology tools of some embodiments of the present invention. [Figure 13A] 1A-1C are schematic diagrams illustrating alternative exemplary wire gripper tools according to some embodiments of the present invention. [Figure 13B] 1A-1C are schematic diagrams illustrating alternative exemplary wire gripper tools according to some embodiments of the present invention. [Figure 14A] 1A and 1B are schematic diagrams illustrating wiring end effectors compatible with interchangeable tools according to some embodiments of the present invention. [Figure 14B] 1A-1C are schematic diagrams illustrating exemplary wire retention elements / wire holders according to some embodiments of the present invention. [Figure 14C] 1A-1C are schematic diagrams illustrating exemplary wire retention elements / wire holders according to some embodiments of the present invention. [Figure 14D] 1A-1C are schematic diagrams illustrating exemplary wire retention elements / wire holders according to some embodiments of the present invention. [Figure 14E] 1A-1C are schematic diagrams illustrating exemplary wire retention elements / wire holders according to some embodiments of the present invention. [Figure 14F] 1A-1C are schematic diagrams illustrating exemplary wire retention elements / wire holders according to some embodiments of the present invention. [Figure 14G] 1A-1C are schematic diagrams illustrating exemplary wire retention elements / wire holders according to some embodiments of the present invention. [Figure 15] 1 is a flowchart illustrating an exemplary verification method according to some embodiments of the present invention. [Figure 16] 1 is a flowchart illustrating a wiring method with an exemplary wiring end effector module having interchangeable tools according to some embodiments of the present invention. [Figure 17A] 10 is a flowchart illustrating an exemplary wiring end effector module wiring method where the wire has a ferrule, according to some embodiments of the present invention. [Figure 17B] 10 is a flowchart illustrating an exemplary wiring end effector module wiring method where the wire has a ferrule, according to some embodiments of the present invention. [Figure 18] 1 is a flowchart illustrating a wiring method using a wiring arm module according to some embodiments of the present invention. [Figure 19] FIG. 2 is a schematic diagram illustrating exemplary data flow and operation of the autorouting system of some embodiments of the present invention. [Figure 20A] FIG. 1 is a schematic diagram illustrating a wiring process with two automated mechanical arms, according to some embodiments of the present invention. [Figure 20B] FIG. 1 is a schematic diagram illustrating a wiring process with two automated mechanical arms, according to some embodiments of the present invention. [Figure 21] 10 is a graph illustrating exemplary phases of wire insertion into an electrical terminal connector of a component identified by a sensor in a gripper, according to some embodiments of the present invention. [Figure 22A] 10A-10C illustrate three different examples of forces sensed by a gripper in three different scenarios, according to some embodiments of the present invention. [Figure 22B] 10A-10C illustrate three different examples of forces sensed by a gripper in three different scenarios, according to some embodiments of the present invention. [Figure 22C] 10A-10C illustrate three different examples of forces sensed by a gripper in three different scenarios, according to some embodiments of the present invention. [Figure 23] 10 is a graph illustrating data received from a sensor during different tests, according to some embodiments of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0068] The present invention, in some embodiments of the invention, relates to interchangeable tools for robots, and more particularly, but not exclusively, to interchangeable tools for robots in wiring systems.

[0069] [overview] An aspect of some embodiments of the present invention relates to a robotic wiring system and automated exchange of dedicated wiring tools. In some embodiments, the robotic wiring system (hereinafter simply referred to as the "wiring system") includes one or more robotic mechanical arms (hereinafter simply referred to as the "robot arm") having interchangeable end effectors. In some embodiments, the robotic arm includes a connector configured to reversibly connect one or more tools to the robotic arm. In some embodiments, the connection of the tool to the robotic arm includes a mechanical connection and / or an electrical connection. In some embodiments, the robotic arm is one or more of a manipulator, a Cartesian gantry system, and a multi-axis platform. In some embodiments, the connector includes an actuation mechanism for the tool. In some embodiments, the tool itself includes the actuation mechanism necessary for its drive. In some embodiments, the tool is configured for wiring operations. In some embodiments, the tool is configured to hold any type of hardware required for complete wiring of a device. For example, the tool is configured to hold and / or manipulate one or more of electrical components, electrical wires, connectors, ferrules, and cables.

[0070] In some embodiments, the wiring system is configured to facilitate tool exchange for performing wiring operations, and in some embodiments, dedicated tools are located in close proximity to the wiring area, more specifically, within reach of one or more robotic arms.

[0071] In some embodiments, the wiring system includes multiple tools to allow the automated system to hold any type of wire and ferrule, as well as tubing, fiber optic cable, connectors, and cables. A potential advantage of the system is the possibility of easily designing new tools as needed. In some embodiments, the tools include one or more sensors to provide feedback regarding the force and / or torque sensed through the tools. In some embodiments, the tools are designed to be slender, allowing access to narrow and / or tight components and ducts within electrical cabinets. In some embodiments, the system is configured to use technical tools, for example, for quality assurance tasks (e.g., continuity and data transfer). In some embodiments, different tools include one or more marks that the system uses to identify different tools, potentially preventing the system from using non-genuine parts.

[0072] In some embodiments, the automated wiring system includes one or more sensors to monitor the wiring process and automatically replace tools in the end effector as needed to continue and complete the wiring process. In some embodiments, the system receives in advance the order in which the replaceable tools will be used. In some embodiments, the system is configured to detect a problem using one or more sensors, evaluate the problem, select an appropriate tool to address the problem, perform the tool replacement, resolve the problem, and continue the wiring process as previously programmed. In some embodiments, the problem is resolved using one or two of the robotic arms. In some embodiments, when two robotic arms are used, the two robotic arms work together to resolve the problem.

[0073] Before describing at least one embodiment of the present invention in detail, it is to be understood that the invention is not necessarily limited in its application to the details of construction and the arrangement of components and / or methods set forth in the following description and / or illustrated in the drawings and / or examples. The invention is capable of other embodiments or of being practiced or carried out in various ways.

[0074] Reference is now made to FIG. 1, which shows a schematic diagram of an exemplary autorouting system, according to some embodiments of the present invention.

[0075] In some embodiments, the system includes electrical design software used on one or more of electronic devices 102, such as a personal computer, a tablet, a mobile phone, and a dedicated design station. For simplicity, the software and electronic devices are hereinafter referred to as a design console.

[0076] In some embodiments, the system includes a database 104 having one or more of technical electrical data, electrical designs, mechanical drawings, business data, and the like.

[0077] In some embodiments, the system includes one or more of the automated electrical wiring units / systems / modules 106, which are further described below.

[0078] In some embodiments, the software on the electronic device 102, the database 104, and the one or more automatic electrical wiring units / systems / modules 106 communicate with each other by one or more of a wired connection, a wireless connection, and a wireless connection via a cloud server 108. In some embodiments, the database 104 and the cloud server 108 are one.

[0079] [Design console example] In some embodiments, the design console 102 includes a graphical interface unit (GUI) dedicated to virtually designing an electrical cabinet. In some embodiments, a user enters all necessary information and requirements related to the project, including one or more of the required switches, knobs, and displays, the need for heat dissipation, radio frequency interference, and electrostatic discharge protection, the required number of wires, connectors, conduits, wire types, which may include wire gauge, color, solar radiation type, end piece type, etc., and the components within the cabinet may include various electrical and electronic components such as switches, molded case breakers, relays, couplers, drivers, computer components, circuit boards, etc.

[0080] In some embodiments, the design console 102 manages all design data, including bills of materials and connection lists, or related documentation such as assembly instructions and data sheets. 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 that contains a component-based parts library that ensures that only actual parts are used and optionally helps drive the design with automatic part selection.

[0081] In some embodiments, the design console 102 is configured to help a user create multiple drawings required for wiring an electrical cabinet, such as an electrical schematic diagram showing what types of wires are connected to where within the electrical cabinet, and a mechanical drawing (typically performed by an electrician and / or a mechanical engineer) showing a layout model of the various components within the electrical cabinet.

[0082] In some embodiments, database 104 contains a library of parts that previous users have used and / or inserted into the library. In some embodiments, the library of parts contains technical information about specific parts, each part represented in one of the blueprints. For example, an electrician might use a specific part from the library (such as a molded circuit breaker) for a specific wire connection (shown in an electrical schematic), and a mechanical engineer might use the part's location to identify the physical location of the wire entry point.

[0083] In some embodiments, the design console 102 is operated by, for example, a production engineer, who integrates both the electrical schematics and the mechanical drawings into a single design and uses this design to operate the automated electrical wiring unit / system 106 for assembly. In some embodiments, the system itself automatically merges both designs and, optionally after approval by the production engineer (or other dedicated personnel), provides them to the automated electrical wiring unit / system 106 for assembly. In some embodiments, a simulation is also performed prior to actual assembly by the automated electrical wiring unit / system 106. In some embodiments, data continuity is maintained throughout the process, from cabinet design, including, for example, designing and merging the electrical schematics and mechanical drawings, to component installation, wiring design, and the actual wiring of the cabinet, including the operations performed by each part of the system. For more information about data continuity, the merging process, and other processes, see www(dot)smart-cabinet-building(dot)com / en / index.jsp, the contents of which are incorporated herein by reference in their entirety.

[0084] In some embodiments, if there are no engineering drawings and only a bill of materials (BOM), an empty (unwired) cabinet can be scanned and analyzed using specialized scanning software to recognize the cabinet and / or component type. In some embodiments, the system then creates a wiring blueprint based on the scan and BOM.

[0085] In some embodiments, the design console 102 includes a "built-in real-time design rule checker" configured to check for and potentially prevent errors. In some embodiments, a potential benefit of this feature is potentially avoiding errors upfront, which is better than discovering errors later in production. In some embodiments, the design console has basic functionality including device duplication prevention, short circuit prevention, design reuse with centrally stored subcircuits or modules, automatic and parallel connections, drawing and area saving, loading, copying, rotating, and mirroring, extensive functionality for exchanging symbols and components, component-driven intelligent part libraries, ensuring only valid parts are used in a design, simple and complex transformation and option management, online cross-referencing of connections and devices, object and text hyperlinking, user-defined attributes, user-defined grid sizes, fonts, and line types, and dynamic zoom and pan.

[0086] In some embodiments, the design console includes the design and documentation of wire plans and harness layouts. In some embodiments, this design allows individual conductors to be combined to form new wires or harnesses. In some embodiments, shielding and twisted pair construction can also be added to wires and automatically shown in the schematic. In some embodiments, views allow for alternative documentation of devices, such as one-line diagrams, wiring diagrams, and wire plans. For example, a connector can be represented as a single pin in the schematic diagram and as a complete connector in the wire plan. In some embodiments, changes to any of the views instantly update all other views, ensuring all documentation is synchronized.

[0087] In some embodiments, the design console includes block functionality. In some embodiments, blocks represent components, rack equipment, black boxes, PCBs, and systems and subsystems throughout the hierarchy. In some embodiments, connector pins are dynamically added to blocks, and signal information is displayed next to them. In some embodiments, blocks represent hierarchical systems and subsystems, allowing users to tunnel through blocks to lower levels, and signals and connections can pass between levels and sublevels. In some embodiments, the hierarchy enables top-down and bottom-up design, promoting design reuse and providing managers with a system-level overview. In some embodiments, specialized representations of connectors, such as those used in the aerospace and automotive industries, are automatically created using dedicated extensions.

[0088] In some embodiments, the system includes instructions for validating the design according to specific standards and / or codes, e.g., ensuring all ground bars are properly positioned and sized according to state / national / CE / UL regulations, for example.

[0089] In some embodiments, the system is configured to allow a user to manage electrical schematics and mechanical drawings at and by the design console 102. In some embodiments, a user provides and / or inserts rules for the electrical schematics and / or mechanical drawings into the design console 102. In some embodiments, the rules are related to one or more government-mandated standards, special client requirements, technical limitations, and any other rules the user wants to add to the design console 102. In some embodiments, the user then designs the electrical schematics and / or mechanical drawings 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, designs are created elsewhere and manually inserted into the design console 102. In some embodiments, upon receiving the designs, the design console 102 performs checks on the designs to ensure they comply with the established rules. In some embodiments, if there are problems with any of the designs, the system notifies the user. In some embodiments, corrections are made in the design console 102 itself. In some embodiments, the user brings in a revised design created elsewhere. In some embodiments, once the design is approved, the design console 102 creates the original wiring plan by merging the electrical schematic and mechanical drawing. In some embodiments, after merging, the design console 102 optionally performs additional checks of the rules of each design to ensure that all rules are still maintained. In some embodiments, the system then continues to prepare a robot wiring plan.

[0090] In some embodiments, a 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 schematics 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 recheck the drawings.

[0091] In some embodiments, the design console allows for the transfer of electrical cabling / wiring details (components, connectors, terminals, splices, netlist information) to an automated electrical wiring unit / system 106 .

[0092] In some embodiments, the design console allows users to work in either two or three dimensions. In some embodiments, the design console allows users to layout components within a panel enclosure. In some embodiments, intelligent automatic snap points make it easy to place parts in the correct location, and lockouts and height restrictions can prevent damage. In some embodiments, a potential advantage of the system is that it provides an easy-to-use system, potentially meaning that users do not need to understand MCAD tools. In some embodiments, the software is configured to automatically create a design of the route of wires through ducts within the panel, taking into account the shortest route and any separation requirements. In some embodiments, the duct fill volume is also checked during design creation. In some embodiments, the length of each wire is calculated, and that information is passed to the automated electrical distribution unit / system 106.

[0093] In some embodiments, based on the design and routing of multiple wires, cable placement priorities are generated based on one or more of the following example aspects: physical constraints (e.g., inserting wire 11 before 12 into a device to avoid collisions / obstacles), and sequence optimization based on other priorities (e.g., reducing cycle time).

[0094] In some embodiments, the design console utilizes a simplified model of the electrical panel design to check for clashes in the complete mechanical design. In some embodiments, this functionality allows a full digital mockup to evaluate spacing requirements, clash / interference detection, and error prevention. In some embodiments, multiple users can utilize the system simultaneously, optionally independently or collaboratively. In some embodiments, the design console ensures that all changes are tracked and documented. In some embodiments, alternative revisions of the design are compared to 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 the form of a wire list, including route and length information for the automated electrical distribution unit / system 106.

[0095] [Example of a simulation module] In some embodiments, the design console comprises a simulation module including 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.

[0096] In some embodiments, the simulation module runs a simulation to potentially prevent collisions between the system (e.g., a robotic arm) and cabinet components. In some embodiments, the simulation module runs a simulation to validate various sequences 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 a bill of materials (BOM) within the electrical cabinet. In some embodiments, the simulation module is used to validate that all blueprints are used to design the wiring of the electrical cabinet. In some embodiments, the simulation module is used prior to running the automated electrical wiring unit / system 106. In some embodiments, the simulation module creates code and optionally downloads it to the automated electrical wiring unit / system 106. In some embodiments, the simulation module is used to set the cost of cabinet assembly to the end user. In some embodiments, the simulation is used to optimize raw material usage, for example, minimizing the total length of wire used to conserve copper.

[0097] [Example of dividing work into macro and micro processes] In some embodiments, the design console software includes instructions for dividing the overall autorouting process into multiple macroprocesses, including multiple microprocesses. In some embodiments, an optimization process, including the use of simulation, ensures that the macroprocesses and microprocesses are performed in an optimal manner according to the task, optionally by optimizing most, if not all, of the macroprocesses and microprocesses. In some embodiments, the autorouting system may perform multiple optimization processes using micro- and macro-behavior analysis by AI algorithms to reduce setup time. In some embodiments, the AI ​​algorithm is configured to analyze errors and / or repeat faults in wiring performance and optionally correlate them with specific components and / or locations within the panel to provide proactive solutions and / or warnings when creating blueprints for the panel's wiring.

[0098] In some embodiments, the micro-processes depend on the particular tools used, but similar macro-processes can use different micro-processes for the actual devices in the automated electrical wiring unit / system 106.

[0099] In some embodiments, the micro-operation library is part of a third entity that provides the tool with its corresponding micro-operations, for example, a gripper can be electrically operated to provide a micro-operation that activates a motor (alternatively, a pneumatic actuator may be used) to perform the gripping task. In some embodiments, the micro-operation can include a sensing module, such as to identify when the wire has actually been secured in place.

[0100] [Example of automatic wiring unit / system 106] In some embodiments, after the electrical cabinet is drafted and / or designed, the final design is passed to an automated wiring unit / system 106 for assembly. In some embodiments, the electrical cabinet may be a panel, a system, an appliance, or any other device that requires wiring.

[0101] 2, a schematic diagram of an exemplary automated wiring unit / system 106 is shown, according to some embodiments of the present invention. In some embodiments, the exemplary automated wiring unit / system 106 includes one or more modules as part of and / or within a main casing or station 202, such as 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, and a software module 214.

[0102] [Example of software module 214] In some embodiments, the automatic wiring unit / system 106 includes a software module 214 that communicates with all of the different modules within the wiring unit / system 106 and with external systems. In some embodiments, the software module 214 receives a design plan from a design console (external system) and activates the different modules within the automatic wiring unit / system 106 to execute the wiring plan.

[0103] In some embodiments, the software module 214 is also responsible for debugging the system and performing and / or scheduling system maintenance.

[0104] In some embodiments, the software module 214 includes, among other things, on-site simulation software that allows for validation of a process (or portions thereof) before execution and during actual execution.

[0105] In some embodiments, a 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, color, etc. are also edited by the user. In some embodiments, a user can add testing and / or QA routines to the runtime software.

[0106] [Example of Panel Handling Module 210] In some embodiments, various panel handling modules can support the process of loading and unloading panels into the system 106. In some embodiments, when the main casing is vertical (as shown in the example of FIG. 3), the panel handling module 210 is configured to rotate the electrical cabinet about its axis within the automated wiring unit / system 106 to facilitate one or more of loading the electrical cabinet, unloading the electrical cabinet, and allowing user access to outfit the electrical cabinet while it is within the automated wiring unit / system 106. In some embodiments, the panel handling module can hold the panel in a vertical orientation (e.g., as shown in FIG. 3) and / or a horizontal orientation (e.g., as shown in FIG. 4).

[0107] In some embodiments, the panel handling module is used in combination with an automated or semi-automated loading / unloading system. In some embodiments, the loading / unloading system moves linearly rather than rotationally.

[0108] [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 operations to ensure valid functionality of the automatic wiring unit / system 106. In some embodiments, the functions monitored are one or more of: validating wire insertion, validating the position of electrical components within an electrical cabinet, verifying wire routing, validating the operation of locking mechanisms in electrical connectors of electrical components (e.g., by validating the torque of screws holding wires in connectors), and optionally validating wire connections and validating electrical integrity.

[0109] In some embodiments, the automatic wiring machine includes multiple sensors for tactile feedback, force feedback, and moment / torque feedback, which may increase the insertion of wires into valid locations and may shorten the validation process.

[0110] In some embodiments, vision and / or optical systems are 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 an end effector or through a specific tool that can be attached (automatically or manually) to the wiring arm module. For example, the lock actuation mechanism that activates the locking mechanism in the connector includes a screwdriver that actuates a screw to compress the wire. In some embodiments, electrical current is used to perform continuity / resistance tests, for example, by touching two components (one on each arm) and validating continuity through resistance and / or current parameters.

[0111] In some embodiments, the automatic wiring system utilizes deep learning algorithms for component location and identification, which may increase position validation and insertion of wires in valid locations and may reduce the time of the validation process.

[0112] In some embodiments, because some of the components may be partially hidden (or only partially visible) to the QA system, the system's deep learning (D / L) algorithms use previously learned processes to identify parts and estimate their location.

[0113] In some embodiments, for example, if a particular connector normally has a ground wire going to port A, but in one instruction set the ground wire is (mistakenly) routed to port B, the D / L algorithm is used to predict possible errors in the routing system and the system issues a warning, or alternatively other logic is used to check whether port B can also accept a ground wire.

[0114] In some embodiments, the automated wiring system may utilize reinforcement learning for impedance controlled flexible wire insertion to increase wire insertion in reasonable locations.

[0115] In some embodiments, the automatic wiring system uses a search routine with a feedback system to create openings (ports) for inserting wires into connectors of components. In some embodiments, the automatic wiring system uses a vision system with or without other sensors to create connector openings in the components before and / or during wire insertion. In some embodiments, the automatic wiring system performs a dry run (scan) on the components to validate the locations of connector openings in the components (e.g., using various sensors, such as visual, optical, tactile, etc.) and provide corrective delta positions before performing the insertion routine.

[0116] [Wire Preparation Module 204] In some embodiments, the automatic wiring unit / system 106 includes a 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 a separate module, optionally external to the automatic wiring unit / system 106. In some embodiments, the wire preparation module 204 is responsible for preparing wires for incorporation into electrical cabinets by the automatic wiring unit / system 106.

[0117] In some embodiments, the wire preparation module 204 includes one or more of the following components: a plurality of wire stocks, one or more wire manipulators with rails that allow the wire manipulators to move between modules (see below), at least one wire stripper module, a plurality of wire end connector (wire head) attachment modules, a wire cutter, and a frame configured to house all of the modules and components of the wire preparation module 204.

[0118] In some embodiments, wire preparation module 204 includes a wire marking device configured to add personalized markings to the wires being prepared. For example, the wire marking device can add numbers, letters, symbols, etc., via a laser, sticker, or any other printing machine configured to print on the surface of the wire or add a sticker or sleeve to mark the wire. In some embodiments, a potential advantage of the wire marking device is that it can potentially make it easier to locate a particular wire in a cabinet at a later time.

[0119] [Example of a wire feeding unit] In some embodiments, wires are provided that are ready to be used by providing pre-cut wires ready to be routed into the 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 in advance by a wire preparation module. In some embodiments, the ready-to-use wires 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, an automated system invokes the use of a wire delivery unit to provide the wires to be plugged into the electrical cabinet. In some embodiments, dedicated fixtures are used to present the pre-cut wires to the system, e.g., fixtures are constructed with provisions to hold the wires according to their length or according to their order / sequence. In some embodiments, the wire delivery unit is optionally movable and can be attached to the system as needed. In some embodiments, the wire delivery unit can optionally service multiple systems. In some embodiments, the wire preparation module includes a hand-off mechanism to deliver and / or present the wire(s) to the wiring system, e.g., using a manipulator, dual arms, pneumatic shaft, etc.

[0120] [Example of wiring system] Reference is now made to Figures 3 and 4, which respectively show schematic diagrams of vertical and horizontal automatic routing systems according to some embodiments of the present invention.

[0121] Reference is now made to Figure 3, which illustrates an exemplary vertical automated wiring system, in accordance with some embodiments of the present invention. As noted above, the exemplary automated wiring system is configured to allocate an erected electrical cabinet around which multiple modules operate to perform automated wiring operations.

[0122] Reference is made to FIG. 4 , which shows a schematic diagram of an exemplary horizontal automated wiring system with a dedicated wire preparation module according to some embodiments of the present invention. In some embodiments, the system is mounted on a horizontal platform 202, on which all necessary equipment is located. As noted above, in some embodiments, the system includes one or more wiring arm modules 206 (two are shown in FIG. 4 ), optionally including a wiring end effector module 208 and a wire preparation module 204, both configured to prepare connection-ready wires 402 (for example) for use in wiring a panel 404, similar to those disclosed above. In some embodiments, the system optionally includes a depth camera 406 configured to monitor the wiring operation of the system. In some embodiments, the wiring method is similar to that disclosed elsewhere herein.

[0123] [Fine Motor Skills and Wiring] Before describing at least one embodiment of the exemplary wiring arm module 206 and exemplary wiring end effector module 208 of the present invention in detail, the inventors wish to convey one of many potential challenges in robotic automation performance in general, and in robotic automation of electrical wiring and robotic wiring operations in particular. The inventors have discovered that properly routing electrical wires into an electrical cabinet requires a certain level of dexterity and / or perceptual ability (meaning a high level of wire manipulation ability), and clearly in some cases requires at least two hands. For example, a technician and / or user must utilize their somatosensory system (e.g., touch) to hold a wire with one hand, insert the wire alone or with a wire head into an electrical receptacle or electrical terminal connector of a component, and perform a locking action with the other hand to lock the wire into the receptacle. It should be understood that the terms “electrical receptacle” and “electrical terminal connector” are interchangeable, and when referring to either, they both refer to the same thing: an object within a component configured to accept a wire for the purpose of connecting and / or holding the electrical wire to the component. Furthermore, depending on the type of wire end, when inserting the wire into the outlet, only the necessary force needs to be used to, on the one hand, lock and hold the wire in the outlet, and, on the other hand, avoid deformation of the wire due to the application of excessive force. It is also common in the art that, after the locking action has been performed, the user "feels" that the wire is fixed in place by pulling the wire slightly. In the following paragraphs, exemplary actions performed by humans are described to enable those skilled in the art to understand the challenges of translating seemingly simple tasks performed by humans into robotics.

[0124] In some embodiments, the robotic system has fine motor skills (or dexterity). In some embodiments, the automated wiring system (in general) and wiring arm module of the present invention have one or more of the following technical characteristics:

[0125] Joints: In some embodiments, the arm module, together with the wiring end effector module, includes multiple joints that provide the system with multiple degrees of freedom of movement. Referring now to FIG. 5A , an exemplary wiring arm module 206 including multiple joints is shown, according to some embodiments of the present invention. In some embodiments, the wiring arm module 206 includes multiple joints 502, 504, 506. In some embodiments, the joints provide multiple degrees of freedom of movement. For example, joints 502, 504, 506 can potentially provide between four and eight degrees of freedom of movement, 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 that more or fewer joints can be used. In some embodiments, the system can be Cartesian with a rotating end effector or fully articulated.

[0126] Exemplary Sensory Capabilities: In some embodiments, the arm module and wiring end effector module comprise multiple sensors (see below) configured to monitor the module's interaction with the wires and / or wire cabinet. In some embodiments, the arm module and wiring end effector module are actuated using a combination of motors, sensors, and software that allows for a compliance-based mechanism with antagonistic elastic actuation, as opposed to rigid linkage-based robotic grippers. In some embodiments, this allows for greater variability in gripping force control. In some embodiments, the software includes information about payload weight / stiffness and structure, as well as programs that enforce correct functioning of the gripper (grasp blueprinting) without overshoot.

[0127] In some embodiments, parts of the arm and / or gripper are automatically modified for dedicated tasks, e.g., to hold different tools, such as tweezers or cutters. Grasp and slide functionality: When performing wiring operations, humans use haptic feedback to secure the cable to the connector / device, and a typical motion cycle includes the following (see Figures 5B-5F): · The contact force is zero and before increasing during insertion, a radial force is applied to the wire (radial force, Figure 5B) and an insertion force (axial force, Figure 5C) is applied to grasp the wire; At a certain peak force (determined by the user's experience), the human "feels" the wire is inserted into the component connector (peak force, Figure 5D). At this point, the axial force is usually countered by fully inserting the wire into the component connector; After the wire is secured in the connector, the user pulls the wire back with a certain force (to feel whether it is firmly secured) (user pull, Figure 5E); Next, the user reduces the radial force (grip) on the cable, allowing it to slide axially within the hand (Figure 5F). Typically, the user will feel the cable sliding without releasing the wire.

[0128] In some embodiments, these actions are performed using what are referred to herein as grasp and slide functions.

[0129] In some embodiments, the wire arm module 206 with the wire end effector module 208 includes multiple motors and sensors that perform force and axial and radial force measurements similar to those performed by a human to provide a system with a high level of dexterity and perception capable of performing wire operations. In some embodiments, the wire end effector module 208 includes one or more optical sensors, such as one or more cameras and / or laser scanners. In some embodiments, the wire end effector module 208 includes multiple 2D and / or 3D cameras.

[0130] [Example of wiring arm module 206] 6A and 6B, a schematic diagram of an exemplary wiring arm module 206 is shown, according to some embodiments of the present invention. In some embodiments, the wiring arm module comprises a base 602 mounted on a rail 604. In this example, the rail 604 comprises two vertical tubes on which the entire wiring arm module moves vertically, as indicated generally by arrow 606. In some embodiments, a mechanical arm 608 mounted on the base 602 comprises multiple arm sections 610, 612 and joints 502, 504, 506. In some embodiments, the end of the mechanical arm 608 is a wiring end effector module 208. Referring now to FIG. 6B, a schematic diagram of two exemplary wiring arm modules 206 in a wiring unit / system 106 is shown, 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 arranging them in this manner is that it provides the necessary space for each mechanical arm to move freely without interfering with the movement of other mechanical arms. In some embodiments, each wire arm module 206 includes a wire end effector module 208 that optionally includes a camera 650. It should be understood that in any of the embodiments of the wire end effector module 208, a camera is an optional addition.

[0131] In some embodiments, the wire arm module is optional, which means that a simpler holder for the wire end effector module 208 can be used. In the following paragraphs, the invention will be described using the example of an automated wiring system with a dedicated wire arm module 206. It should be understood that other types of platforms capable of actuating the wire end effector module 208 can be used and are within the scope of the invention.

[0132] 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, a cartesian gantry-type arm or dual arms are used for the primary motion (XYZ), with fine local motion provided by two or three rotational axes in conjunction with the end effector.

[0133] [Example of Wiring End Effector Module 208] 7A, a schematic diagram of an exemplary wire end effector module 208 is shown, according to some embodiments of the present invention. In some embodiments, the wire end effector module 208 comprises one or more of the following components: a wire retaining element / wire holder 702 (or wire holder) and a wire locking element / wire lock 704. Referring now to FIG. 7B, a schematic diagram of the components of the wire retaining element / wire holder 702 is shown, according to some embodiments of the present invention. In some embodiments, the wire retaining element / wire holder 702 comprises one or more of a base 706 that includes a wire clamping element 708. In some embodiments, the wire clamping element 708 comprises two extensions 710a and 710b, optionally two elongated finger-like extensions, that are coupled together, for example, by an electrical mechanism 712 and / or a pneumatic mechanism. In some embodiments, the length of the two extensions 710a and 710b, as measured from the base to the ends of the extensions 710a and 710b, is about 20 mm to about 200 mm, optionally about 15 mm to about 250 mm, and optionally about 10 mm to about 300 mm. In some embodiments, a potential advantage of having the extensions 710a and 710b about 200 mm in length is that this configuration provides sufficient distance between the end effector and the surface of the panel being wired so that the distal ends of the extensions 710a and 710b may reach the panel being wired without interfering with protruding elements within the panel. In some embodiments, the width of the two extensions 710a and 710b is about 6 mm, e.g., about 3 mm to about 6 mm, optionally about 2 mm to about 8 mm, and optionally about 1 mm to about 10 mm. In some embodiments, a potential advantage of the small width of the two extensions 710a and 710b is that the two extensions 710a and 710b may be able to be inserted into tight and / or crowded places. In some embodiments, the wire clamp element 708 comprises a gimbal block 770 connecting the two extensions 710a and 710b (see further description below regarding the gimbal block 770).In some embodiments, the base 706 includes a motor 714 that enables horizontal movement of the wire retention element / wire holder 702 in the direction generally indicated by arrow 716. In some embodiments, alternatively, or in addition, a wiring arm module provides movement along the schematic arrow 716. In some embodiments, the horizontal movement indicated by arrow 716 is in a direction along the axis of the wire toward the electrical terminal connector. In some embodiments, the base 706 includes one or more motors configured to move the retention element / wire holder 702 in one or more directions. In some embodiments, the movement is along the wire terminal port, which may be at an angle of, for example, 30 degrees, 45 degrees, 90 degrees (or any angle in between) from the plane of the panel.

[0134] Referring now to FIG. 7C , a schematic diagram of sensors located on elongate extensions 710 a and 710 b is shown, according to some embodiments of the present invention. In some embodiments, one or more of elongate extensions 710 a and 710 b include one or more sensors 718 configured to monitor the force applied by elongate extensions 710 a and 710 b to wire 720. In some embodiments, the sensors are embedded in the fingers or body of the end effector. In some embodiments, these sensors enable axial and radial force measurement, as described above, providing the system with a high level of dexterity and perceptual capabilities to perform wire operations similar to those performed by a human. In some embodiments, the sensors are based on, for example, strain gauges, load cells, and / or other devices. In some embodiments, force- or moment-sensing mechanisms (i.e., sensors) are additionally or alternatively located on components connecting the extensions to the device, such as gimbal blocks (see 770 in FIG. 7D ), as shown and described in FIGS. 7D and 7E below.

[0135] In some embodiments, the wire holding element / wire holder 702 holds the wire when it receives the wire from the wire handling portion of the wire preparation module 204 or when it picks up the wire directly from the wire stand.

[0136] In some embodiments, elongate extensions 710a and 710b can be automatically and / or manually interchangeable to accommodate different wire gauges (see below).

[0137] In some embodiments, electrical mechanism 712 includes an anti-collision mechanism to protect the fingers. In some embodiments, electrical mechanism 712 includes a sensor capable of measuring the moment exerted by elongated extensions 710a and 710b during insertion, for example, a moment with a value of about 0.01 NM to about 0.1 NM.

[0138] 7D and 7E, schematic diagrams of an exemplary gimbal block to which extensions are coupled are shown, according to some embodiments of the present invention. In some embodiments, gimbal block 770 comprises multiple components that allow for monitoring of forces applied to extensions 710a and 710b. In some embodiments, the multiple components are one or more gimbals mounted on top of each other but with different axes of motion. For ease of explanation, two axes of motion are described. It should be understood that more gimbals can be used, thereby providing three or more axes of motion that can be monitored. These are also within the scope of the present invention. Returning to FIG. 7D, gimbal block 770 comprises a top block 772 that couples gimbal block 770 to the rest of the device. In some embodiments, a top connector 774 is located below top block 772 and is coupled to top block 772 by screws 776 or the like. In some embodiments, one or more damping springs 796 in communication with one or more button axis load cells 778 are housed between top block 772 and top connector 774. In some embodiments, calibration of the load cell is performed by actuating a damping force calibration set screw 780. In some embodiments, below the top connector 774 is a central block 782. In some embodiments, there is a first gimbal axis 784 inserted into the top side of the central block 782, providing an axis of motion that is horizontally perpendicular to the pin of the first gimbal axis 784 (see below for gimbal block movement). In some embodiments, there is a second gimbal axis 786 inserted into the bottom side of the central block 782 (shown in inserted position). In some embodiments, the second gimbal axis 786 is orthogonal to the first gimbal axis 784. In some embodiments, the second gimbal axis 786 provides an axis of motion that is horizontally perpendicular to the pin of the second gimbal axis 786 (see below for gimbal block movement). In some embodiments, below the central block 782 is a bottom connector 788 that connects to the central block 782 at the top and to a bottom block 790 at the bottom.7D , another set of one or more damping springs associated with / interfacing with another set of one or more button axis load cells are housed between bottom connector 788 and bottom block 790. In some embodiments, extensions 710a and 710b are coupled to bottom block 790.

[0139] In some embodiments, the device includes one gimbal block 770 connecting both extensions 710a and 710b, or in some embodiments, the device includes two gimbal blocks 770, one for each extension, as shown in FIG.

[0140] 7E, a schematic diagram of an exemplary embodiment of a device comprising two gimbal blocks is shown, in accordance with some embodiments of the present invention. In some embodiments, as described above, the gimbal block 770 comprises a first gimbal axis 784 that provides movement of the gimbal block 770 in a first axis and a second gimbal axis 786 that provides movement of the gimbal block 770 in a second axis. FIG. 7E shows a side view of the gimbal block 770, illustrating the movement (arrow 792) enabled by the first gimbal axis 784. FIG. 7E also shows a front view of the gimbal block 770, illustrating the movement (arrow 794) enabled by the second gimbal axis. In some embodiments, the first gimbal axis 784 and the second gimbal axis 786 provide the gimbal block 770 with two distinct axes of rotation. In some embodiments, these rotational axes are used in conjunction with single-axis load cells to measure moments and forces applied to the extensions. In some embodiments, as shown in FIG. 7E, two extensions are each separately coupled to a gimbal block 770, allowing measurement of different forces on each extension. In some embodiments, when the gimbal mechanism reaches its limit of rotation (motion), the system may stop the wire insertion operation and / or take corrective action (moving the device), optionally implying access to the force applied to the extensions (e.g., during a possible collision of the device with an electrical panel).

[0141] 7F, a schematic diagram of an exemplary wire locking element / wire lock 704 is shown, according to some embodiments of the present invention. In some embodiments, the wire locking element / wire lock is configured to interact with a wire locking mechanism of a component after the wire is plugged into that component's respective electrical terminal block in a wire cabinet. In some embodiments, components used in the cabinet may include different types of locking mechanisms in their connectors, e.g., screw terminals, push buttons, and / or push-ins. In some embodiments, when using components with electrical terminal connectors that include push-in locking mechanisms, the wire locking element / wire lock 704 is not needed and is therefore not used. In some embodiments, screw terminals or screw terminal blocks secure the wire to the conductor in the terminal block by tightening a screw to close the clamp. In some embodiments, push button terminal blocks secure the wire to the conductor via a spring clamp that opens by pressing a button. In some embodiments, releasing the button causes the spring to clamp onto the wire. In some embodiments, similar to a push button with a spring clamp, a push-in terminal block allows a wire to be pressed directly into a housing without using a push button to release a spring. In some embodiments, depending on the type of locking mechanism in the terminal block (component), the wire locking element / wire lock 704 includes a dedicated actuator 722. For example, in FIG. 7F , the wire locking element / wire lock 704 includes a flathead screwdriver 722 used to secure a screw terminal block. In some embodiments, the head of the actuator and / or drill bit 722 can be replaced manually or optionally automatically (e.g., by moving the device to an exchange rack, which uses vertical movement 730 to exchange the head of the actuator 722). Referring now to FIG. 7G , a schematic diagram of several possible interactions between the wiring end effector module 208 and different types of terminal blocks (components) having different locking mechanisms for wires in the component's connector is shown.

[0142] Returning to FIG. 7F , in some embodiments, the wire locking element / wire lock 704 includes a motor 724 configured to actuate a dedicated actuator 722. In some embodiments, the motor 724 and dedicated actuator 722 are carried by a base 726, which is further coupled to a second motor 728, which performs the vertical movement, as indicated generally by arrow 730, required for insertion of the dedicated actuator 722 into the terminal block. In some embodiments, although not shown in FIG. 7F , multiple motors are used to provide multiple directions of movement for the wire locking element / wire lock 704. In some embodiments, the wire locking element / wire lock 704 is configured to move up and down, side to side, and back and forth. In some embodiments, a potential advantage of providing such freedom of movement for the locking element 704 is that it enables the device to interact with multiple electrical terminal connectors, each with a different position for accessing the wire locking mechanism.

[0143] In some embodiments, the wire locking element / wire lock 704 comprises a torque sensor configured to monitor the torque force applied by the actuator to a locking mechanism of an electrical terminal connector within the component. In some embodiments, the system includes a database in which specific torque forces associated with specific locking mechanisms of the electrical terminal connector are stored. In some embodiments, the system includes instructions for operating the actuator according to specific parameters that specifically match the torque requirements of a specific locking mechanism and a specific wire gauge of a specific electrical terminal connector.

[0144] [Example of using a wire with an end terminal (wire head) ferrule] 7H and 7I, schematic diagrams of ferrules are shown, according to some embodiments of the present invention. In some embodiments, the wires used in the automated wiring system are wires with built-in ferrules at their distal ends (ferrule wire heads). The ferrule is a ring or cap 7002, optionally with a metallic distal tip 7004, used to encapsulate the exposed distal end of the wire, facilitating handling of the distal end of the wire and connecting the distal end of the wire to an electrical terminal connector of a component. In some embodiments, the ferrule is stiff. In some embodiments, the ferrule is stiffer than the wire itself. In some embodiments, the ferrule is between about 2 and about 10 times stiffer than the wire. In some embodiments, the ferrules can have different dimensions, for example, as shown in FIG. 7H.

[0145] In some embodiments, the ferrule can have a differently shaped metal piece 7004 at its distal end, as shown, for example, in FIG. 7I. In some embodiments, the ferrule includes a cap 7002 that is stiffer than the wire itself, so the wiring end effector module 208 clamps the cap 7002 instead of clamping the wire directly. In some embodiments, a potential advantage of clamping the cap 7002 is that it facilitates easier manipulation of the wire during insertion into the component's electrical terminal connector. Because the wire is flexible, bending the wire during insertion can deflect the head of the wire that needs to be inserted into the electrical terminal connector. Clamping the cap 7002 potentially prevents this. In some embodiments, the ferrule is configured to be fully inserted into the component's electrical terminal connector, meaning that the cap 7002 needs to be fully inserted inside the component's electrical terminal connector to ensure a proper connection.

[0146] In some embodiments, the method of inserting a wire into the electrical terminal connector of the component during use of the wire with a ferrule includes additional steps, as further disclosed below. In some embodiments, the additional actions that must be performed during insertion of the wire including the ferrule include one or more of partially inserting the ferrule into the electrical terminal connector of the component, releasing or partially releasing the ferrule, moving the device rearward, re-clamping the wire at a position distal to the wire relative to the ferrule, and finishing inserting the wire and ferrule into the electrical terminal connector of the component. In some embodiments, prior to releasing the ferrule, the system optionally partially closes a locking mechanism of the electrical terminal connector in the component to partially hold the ferrule in place and potentially prevent the ferrule from exiting the electrical terminal connector.

[0147] In some embodiments, in this case, after re-clamping the wire and before further inserting the wire into the electrical terminal connector, the system releases a locking mechanism on the electrical terminal connector, allowing the wire to be further inserted into the electrical terminal connector. In some embodiments, the wiring end effector module 208 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 can be a third extension configured to extend as needed to hold the wire in place.

[0148] In some embodiments, the extension / end effector is capable of inserting complex shaped ferrules, such as forked or ring ferrules, into the connector.

[0149] [Example of an interchangeable end effector] In some embodiments, as described above, the wire end effector module 208 comprises one or more of the wire retaining element / wire holder 702 and the wire locking element / wire lock 704. In some embodiments, the automated wiring system is configured to replace one or more parts of each of the wire retaining element / wire holder 702 and the wire locking element / wire lock 704 to perform different operations in the automated wiring process. In some embodiments, the replaced part is a tool.

[0150] 8, which shows a schematic diagram illustrating a wire end effector module 800 configured for use with an exchangeable tool according to some embodiments of the present invention. In some embodiments, as described above, the wire end effector module 800 comprises a wire retaining element / wire holder 802 and a wire locking element / wire lock 804.

[0151] In some embodiments, the wire holding element / wire holder 802 comprises one or more of: a force meter 806 configured to sense force from three different axes; and a gripping actuator 808 configured to actuate an exchangeable tool 810 (e.g., a wire holder with two extensions that grip at least one wire 812, a cable holder, a continuity probe, a USB data transfer tool, etc., as disclosed above) held in a tool holder 814 (e.g., a snap-in tool holder).

[0152] In some embodiments, the wire locking element / wire lock 804 includes one or more mechanical driver motors 816 configured to rotate at least one replaceable driver bit 818. In some embodiments, the wire locking element / wire lock 804 includes one or more actuators configured to move the wire locking element / wire lock 804 in one or more directions. For example, FIG. 8 shows a wire locking element / wire lock 804 with two motors: a first motor 820 configured to provide controlled vertical movement (arrow 822) to the wire locking element / wire lock 804, and a second motor 824 configured to provide controlled horizontal movement (arrow 826) to the wire locking element / wire lock 804. In some embodiments, the motors are configured to move different portions in one or more different directions depending on the wiring requirements.

[0153] [Example of locking mechanism for interchangeable tools] 9A and 9B, which illustrate schematic diagrams illustrating a locking mechanism for an exchangeable tool according to some embodiments of the present invention. In some embodiments, a wire retaining element / wire holder 802 comprises one or more locking mechanisms 900 configured to lock in place an exchangeable tool inserted into a dedicated tool holder 814. For example, the locking mechanism 900 comprises a mechanical actuator 902 configured to move a locking pin 904 back and forth. FIG. 9A, for example, illustrates how the locking pin 902 of the locking mechanism 900 locks the exchangeable tool in place, while FIG. 9B, for example, illustrates how the locking pin 902 of the locking mechanism 900 retracts to release the exchangeable tool. In some embodiments, the locking mechanism 900 is further used to provide an electrical connection for a conductive connection tool (see below).

[0154] [Examples of interchangeable tool characteristics] Refer to FIGS. 9C and 9E, which show schematic diagrams of the replaceable tool of the end effector and its characteristics in some embodiments of the present invention. In some embodiments, a replaceable tool configured to grip a wire / component is manufactured to potentially overcome difficulties related to an automatic wiring system.

[0155] For example, in some embodiments, as shown in FIG. 9C, a replaceable tool for gripping a wire has a width small enough to pass through the space within an exemplary duct in which the wire extends. In FIG. 9C, a replaceable tool 910 for gripping wire 912 and positioning it along duct 914 is shown. In some embodiments, at some point, for example, to reach terminal block 916, the wire needs to exit duct 914. In some embodiments, the exemplary duct 914 is periodically open and has an opening width W2 through which wire 912 can enter and exit duct 914. In some embodiments, the replaceable tool 910 for gripping wire 912 has a total width W1 that is smaller than the opening width W2 of duct 914 (W1 < W2). In some embodiments, the total width W1 of the replaceable tool 910 includes about 6 mm, for example, about 3 mm to about 6 mm, optionally about 2 mm to about 8 mm, and optionally about 1 mm to about 10 mm.

[0156] In other examples, in some embodiments, as shown in FIG. 9D, the replaceable tool has a length sufficient to reach an exemplary component while avoiding the risk of collision between the end effector and the panel components. As disclosed in the multiple embodiments described herein, in some embodiments, an exemplary end effector includes multiple parts that together provide an end effector of a certain size. In some embodiments, the size of the end effector may limit the movement and / or distance by which the end effector can approach the panel. In some embodiments, the tool is characterized by having a length that reaches the panel while maintaining a safe distance from the panel and / or components within the panel.

[0157] 9D shows a panel 920 with multiple components 922a-922f, each having a different height (height being the distance a component protrudes from the surface of the panel). Also shown are multiple exchangeable tools 910, the lengths of which allow for reaching the components while maintaining an end effector volume 924 at a spaced or safe distance from the components and / or panel. In some embodiments, the exchangeable tools 910 have an extension length of about 20 mm to about 200 mm, optionally about 15 mm to about 250 mm, and optionally about 10 mm to about 300 mm.

[0158] Due to potential travel limitations due to the size of the end effector, in some embodiments, the distal end of the exchangeable tool 910 configured to grip the wire may have a specialized gripping tip that allows the wire to be gripped at a specific angle. For example, as shown in FIG. 9E , the exchangeable tool 910 has a distal end that grips the wire at an angle of approximately 45° relative to the axis of the extension of the exchangeable tool 910. In some embodiments, the angle may be between approximately 0° and approximately 180°, such as 0° (which is perfectly aligned with the axis, with the wire at the distal end pointing completely downward along the axis of the extension of the exchangeable tool 910), 30°, 45°, 70°, or 90° (which is perpendicular to the axis of the extension of the exchangeable tool 910). In some embodiments, a potential advantage of gripping the wire at a specific angle is that the wire may be positioned at an optimal angle relative to the required insertion location without having to manipulate the entire end effector relative to the panel / component.

[0159] [Example of wire gripping mechanism] 10A and 10B, which illustrate wire gripping mechanisms according to some embodiments of the present invention. In some embodiments, as described above, the automated wiring system includes two extensions (e.g., 710a and 710b in FIG. 7B) configured to interact with the wire during the wiring process. In some embodiments, the two extensions act like "fingers" that grip the wire. In some embodiments, to allow for interchangeable tools in the wire holding element / wire holder 802, the mechanism 808 that actuates the movement (opening and closing) of the two extensions is located outside and / or in separate locations on the extensions themselves, thereby allowing for tool exchange using a single actuation mechanism.

[0160] In some embodiments, the actuation mechanism 808 comprises two pushers 1002 / 1004 configured to apply a controlled force (see arrows in FIG. 10A ) to the extensions 1006 / 1008 of the tool 1010, thereby providing the wire retaining element / wire holder 802 with a controlled grip on the wire 1012. In some embodiments, each extension 1006 / 1008 is connected at a proximal end to a head 1016 of the tool 1010. In some embodiments, the movement of the two extensions 1006 / 1008 toward each other when actuated is arcuate (indicated by the arrows), similar to the movement of tweezers when actuated, for example, because the proximal ends of the two extensions 1006 / 1008 are connected to the head 1016, with only the distal ends free to move.

[0161] 10B-10D, which illustrate three exemplary actuation states of wire grasping tools according to some embodiments of the present invention. In some embodiments, when the actuation mechanism 808 is inactive, the two extensions 1006 / 1008 of the tool 1010 are spaced apart by a distance D1, as shown in FIG. 10B, for example. In some embodiments, the distance between the two extensions 1006 / 1008 when not actuated is between about 3 mm and about 4 mm, optionally between about 2.5 mm and about 4.5 mm, and optionally between about 2 mm and about 5 mm, e.g., 3 mm, 4 mm, 4.7 mm, and any number therebetween. In some embodiments, the opening distance between the two extensions 1006 / 1008 is optionally determined by the wire gauge, with an additional gap added to allow for easy release of the grasped object.

[0162] In some embodiments, upon activation of the actuation mechanism 808 (not shown), the distance between the two extensions 1006 / 1008 of the tool 1010 decreases, for example, to a distance D2, as shown in FIG. 10C . In some embodiments, the distance between the two extensions 1006 / 1008 when activated (i.e., in the closed configuration) is between about 1 mm and about 2 mm, optionally between about 1.5 mm and about 2.5 mm, optionally between about 2 mm and about 3 mm, e.g., 2 mm, 2.7 mm, 3 mm, and any number therebetween. In some embodiments, when the two extensions 1006 / 1008 are in a proximate configuration, they are configured to securely hold a grasped object with minimal friction between them. In some embodiments, the distance between the two extensions 1006 / 1008 of the tool 1010 decreases by applying a constant force F1 to one or more of the extensions 1006 / 1008.

[0163] In some embodiments, an exemplary amount of applied force is about 4 N to about 10 N, optionally about 2 N to about 15 N, and optionally about 1 N to about 20 N. In some embodiments, when the two extensions 1006 / 1008 of the tool 1010 are actuated such that the two extensions 1006 / 1008 of the tool 1010 have a distance D1 between them, the automated wiring system optionally utilizes the wire retention element / wire holder 802 to route the wires along the electrical cabinet. This is because the distance D1 is configured to hold the wires in the distal grooves 1014 of the two extensions 1006 / 1008 without actually grasping them, thereby allowing the wires to "free run" between the grooves 1014 without losing them in the process.

[0164] In some embodiments, as the actuation mechanism 808 (not shown) is further activated, the distance between the two extensions 1006 / 1008 of the tool 1010 further decreases, for example, to a distance D3, as shown in FIG. 10D. In some embodiments, the unactuated distance between the two extensions 1006 / 1008 is between about 3 mm and about 4 mm, optionally between about 2.5 mm and about 4.5 mm, optionally between about 2 mm and about 5 mm, e.g., 3 mm, 4 mm, 4.7 mm, and any number therebetween. In some embodiments, the opening distance between the two extensions 1006 / 1008 is optionally determined by wire gauge, with an additional gap added to allow for easy release of the grasped object.

[0165] In some embodiments, the distance between the two extensions 1006 / 1008 of the tool 1010 is further reduced by applying a constant force F2 to one or more of the extensions 1006 / 1008. In some embodiments, an exemplary amount of applied force is about 4 N to about 10 N, optionally about 2 N to about 15 N, and optionally about 1 N to about 20 N. In some embodiments, when the two extensions 1006 / 1008 of the tool 1010 are actuated such that the two extensions 1006 / 1008 of the tool 1010 have a distance D2 between them, the automated wiring system utilizes the wire retaining element / wire holder 802 to grip the wire (gripping mode). This is because the distance D2 is configured to securely grip the wire in the distal grooves 1014 of the two extensions 1006 / 1008. In some embodiments, insertion of the distal end of the wire into an electrical connector, for example, is performed in this mode. In some embodiments, D1>D2>D3.

[0166] [Example of interchangeable tool 810] In some embodiments, the automated wiring system comprises a dedicated stand 1100 that comprises a plurality of different interchangeable tools 810 and / or a plurality of different interchangeable driver bits 818, as shown, for example, in FIG.

[0167] 12A and 12B, which illustrate an exemplary stand for different interchangeable tools 810 according to some embodiments of the present invention. In some embodiments, the automated wiring system is configured to interchange tools depending on the required task. In some embodiments, the exemplary interchangeable tools can be divided into three main types: wire gripping tools, cable gripping tools, and technical tools. In some embodiments, the exemplary interchangeable tools 810 include one or more of the following: a wire gripper 1202 for small wires (e.g., between 0.5 mm and 1.0 mm in diameter); a wire gripper 1204 for medium wires (e.g., between 2.5 mm and 4.0 mm in diameter); a wire gripper 1206 for large wires (e.g., 6.0 mm or larger in diameter); USB grippers 1208 / 1212, an RJ45 gripper 1210, an HDMI gripper 1214, a continuity test probe 1216, and a USB data transfer tool 1218. In some embodiments, a plurality of exemplary interchangeable tools 810 are held on a stand adjacent to a wiring end effector module 208 configured to move during the wiring process.

[0168] [Example of a wire gripping tool] Refer to FIG. 12C , which illustrates an exemplary interchangeable wire gripping tool according to some embodiments of the present invention. In some embodiments, as described above, the wire gripping tool comprises three main components: a head and two extensions. In some embodiments, the head is configured to be inserted into the holding element of a wire holding element / wire holder element. In some embodiments, the head optionally comprises markings 1220 to allow a user and / or a system to identify the type of tool. For example, FIG. 12C illustrates a zoomed-in view of exemplary markings 1220, showing "T38." In some embodiments, markings 1220 can be numbers that the system identifies using a camera. In some embodiments, markings 1220 can be barcodes and / or RF tags that the system identifies using, for example, a dedicated scanner. In some embodiments, the markings are used to verify the authenticity of the wire gripping tool 1010.

[0169] In some embodiments, each of the two extensions 1006 / 1008 includes a distal end configured to interact with a wire. In some embodiments, the distal end includes one or more grooves 1014 configured to interact with the wire, as described above. In some embodiments, the wire gripping tool 1010 is configured to grip the wire so as to hold the distal end of the wire horizontally (1222) or vertically (1224), as shown, for example, in FIG. 12C . In some embodiments, the same distal end can hold the wire vertically or horizontally. In some embodiments, the wire gripping tool 1010 is already “presented” with the wire in the desired orientation (horizontal / vertical). In some embodiments, the wire gripping tool 1010 is configured to grip the wire, detect its orientation, and correct the orientation, if necessary, by moving the wire gripping tool 1010 accordingly.

[0170] In some embodiments, the distal end can be straight 1226 or "L" shaped 1228. In some embodiments, the distal end is configured to hold a wire, for example, about 0.5 mm to about 6.0 mm in diameter. In some embodiments, different wire gripping tools 1010 are configured to grip, for example, a wire gripper tool 1202 for small wires (e.g., between 0.5 mm and 1.0 mm in diameter), a wire gripper tool 1204 for medium wires (e.g., between 2.5 mm and 4.0 mm in diameter), and a wire gripper tool 1206 for large wires (e.g., 6.0 mm or larger in diameter).

[0171] [Example of a cable gripping tool] 12D, which illustrates exemplary interchangeable tools configured to grip technology cables according to some embodiments of the present invention. In FIG. 12D, exemplary USB gripper 1208, RJ45 gripper 1210, and HDMI gripper 1214 are shown gripping respective technology cables. In some embodiments, the tools are configured to manipulate (e.g., grasp and position) tubes, pipes, fiber optic elements, and any other necessary objects.

[0172] [Examples of technical tools] 12E, which illustrates an exemplary technology tool according to some embodiments of the present invention. In some embodiments, the wiring system includes a dedicated continuity test probe 1216 configured to assess whether wires within an electrical cabinet are properly connected. In some embodiments, after a particular electrical line is assembled by the system, the system assesses whether the wires are properly connected using the continuity test probe 1216. In some embodiments, the wiring system includes a dedicated USB data transfer tool 1218 used, for example, to assess whether a USB port is functioning properly, install and / or update software for electronic components within the electrical cabinet, etc. In some embodiments, the interchangeable technology tool includes a dedicated power / data transfer connector 1230 located on the tool's connector.

[0173] In some embodiments, specialized tools are designed with special geometries to access difficult / narrow areas. For example, offset tools where the wire tip / ferrule location is offset from the center of the end effector. Another example is slim tools required for specific tasks, such as moving between wires, moving between components, and reaching components at specific angles, as shown in Figures 9C and 9E. Optionally, in some embodiments, longer tools may be required to access connection points adjacent to protruding objects. Optionally, in some embodiments, curved or hooked tools may be used to access behind obstructions.

[0174] [Example of dedicated calibration of end effectors and exchangeable tools] In some embodiments, due to differences in (for example) shape and / or role of certain interchangeable tools, dedicated calibration operations are performed beforehand and / or before and / or during use of the automated wiring system. In some embodiments, as described above, the end effector comprises one or more sensors configured to monitor, for example, the forces applied to the end effector, the forces required for correct positioning of the component / wire in the panel, and the forces applied to the end effector to detect collision of the end effector with the component / panel.

[0175] In some embodiments, one or more sensors are located on the end effector itself (e.g., at the base of the end effector above and / or near the adapter of the replaceable tool) and are not removed and / or replaced when the replaceable tool is replaced. Thus, in some embodiments, the one or more sensors are fixed to the end effector, requiring dedicated calibration for and / or accounting for replaceable parts and / or tools. In some embodiments, different replaceable tools require force monitoring, for example, because the force required to insert a wire into a terminal block may be different from the force required to insert a USB into a USB port. Additionally or alternatively, the length of different replaceable tools also affects the monitored force, even if they are replaceable tools with the same function (e.g., a long wire holder and a short wire holder).

[0176] In some embodiments, a potential advantage of performing calibration is that it allows for monitoring of moments and torques applied to the tool (e.g., of the two extensions) during the wiring process. In some embodiments, the moments and torques depend on the geometry and kinematics of the tool, and in some embodiments, specific and personalized calibration is required for each tool. In some embodiments, additionally or alternatively, the gripping (pinch / holding) force of the tool also depends on the geometry and kinematics of the tool, and in some embodiments, specific and personalized calibration is required for each tool.

[0177] Thus, in some embodiments, personalized calibration is performed taking into account the role and physical characteristics of the exchangeable tool. In some embodiments, calibration is performed at the factory. In some embodiments, calibration is performed before performing a particular wiring process. In some embodiments, calibration is performed during the wiring process. In some embodiments, calibration information is gathered by performing one or more tests, analyses (e.g., finite element or linear calculations), and simulations.

[0178] [Example of an alternative wire gripper tool] 13A and 13B, which illustrate schematic diagrams of an exemplary alternative wire gripper tool according to some embodiments of the present invention. In some embodiments, the exemplary alternative wire gripper tool 1300 includes a head 1302 similar to the head shown in, for example, FIGS. 10A-10D. In some embodiments, the exemplary alternative wire gripper tool 1300 includes a fixed extension 1304 having a proximal end connected to the head 1302 and a distal end having a wire housing 1306. In some embodiments, the exemplary alternative wire gripper tool 1300 includes a movable extension 1308 configured to move up and down (see arrow 1310) parallel to the fixed extension 1304.

[0179] In some embodiments, the movable extension 1308 comprises a distal end 1312 configured to merge with the wire housing 1306 at the distal end of the fixed extension 1304 to enclose the wire 1314 within the wire housing 1306. In some embodiments, as described with respect to FIGS. 10B-10D , the distance that the movable extension 1308 moves corresponds to an open configuration (e.g., the configuration shown in FIG. 13A ) or a closed configuration (the configuration shown in FIG. 13B ), where in the closed configuration the distance can be a distance that contains the wire 1314 within the wire housing 1306 while allowing the wire 1314 to “run freely” within the wire housing 1306, or a distance that tightly grips the wire 1314 within the wire housing 1306.

[0180] In some embodiments, the mechanism for moving the movable extension 1308 is mechanical, such as using a pulley mechanism 1316, as shown generally in Figures 13A and 13B. In some embodiments, the mechanism for moving the movable extension 1308 is electrical, such as using one or more electric motors and gears.

[0181] In some embodiments, a potential advantage of the exemplary alternative wire gripper tool 1300 having a longitudinally closing mechanism is that the assistive force provided by such gripping can aid in the insertion of the distal end of a wire into an electrical connector. Additionally, as described elsewhere herein, the mechanism can assist in verifying that the distal end of a wire is properly attached to an electrical connector by providing a delicate “pull / push” action on the wire and detecting resistance. This configuration also potentially aids in placing a wire into a duct, as it can guide the wire through the duct while firmly gripping the distal end, and, if two arms are used, can allow the wire to “free run” within the wire housing 1306 while still providing “direction” to the wire being pulled.

[0182] 14A, which illustrates another exemplary wiring end effector having interchangeable tool capabilities according to some embodiments of the present invention. In some embodiments, as described above, the exemplary wiring end effector includes a wire retaining element / wire holder 1402 and a wire locking element / wire lock 1404.

[0183] Also, in some embodiments, as described above, the wire locking element / wire locking portion 1404 includes a driver unit 1406 (not shown) with torque control and at least one driver head 1408 to drive screws as needed during the wiring process.

[0184] Reference is made to Figure 14A and Figures 14B-14G, which illustrate a wire retaining element / wire holder 1402 according to some embodiments of the present invention. Figure 14B illustrates an exemplary wire retaining element / wire holder 1402 in isolation. Figures 14C and 14D illustrate exemplary portions of the wire retaining element / wire holder 1402. Figures 14E, 14F, and 14G illustrate exemplary portions of an exemplary tool 1414. In some embodiments, the wire retaining element / wire holder 1402 includes a multi-axis sensor 1410 configured to monitor three-dimensional movement of the wiring tool.

[0185] In some embodiments, the wire holding element / wire holder 1402 comprises a tool changer 1412 configured to allow for the exchange of tools 1414 necessary to perform the wiring process. In some embodiments, the wire holding element / wire holder 1402 comprises one or more sensors 1418 configured to monitor the operation of one or more portions of the wire holding element / wire holder 1402. In some embodiments, the wire holding element / wire holder 1402 comprises one or more tool actuators 1416 configured to actuate tools during the wiring process.

[0186] In some embodiments, the wire retaining element / wire holder 1402 includes a restraining actuator 1422 configured to block the tool in a certain position. For example, after the actuator 1416 closes the tool to grip the wire, the restraining actuator 1422 can hold the tool in the closed position to prevent accidental release of the wire. As another example, if the wiring process requires the tool to be kept slightly open but not completely open (e.g., to run along the wire without actually gripping it), the actuator 1416 can partially close the tool to loosely grip the wire, and then the restraining actuator 1422 can hold the tool in the partially closed position to keep the wire loosely gripped while preventing accidental release of the wire.

[0187] In some embodiments, the wire retaining element / wire holder 1402 includes a tool lock actuator 1424 configured to lock the tool shaft 1420 of the tool 1414 within the wire retaining element / wire holder 1402 .

[0188] 14E, 14F, and 14G, which illustrate schematic diagrams of mechanisms for actuating an exemplary tool 1414 according to some embodiments of the present invention. In some embodiments, the exemplary tool is configured to grip a wire using a "scissor mechanism." FIG. 14E illustrates an example of how the "scissor mechanism" is activated. In some embodiments, the "scissor mechanism" comprises a spring 1426 connected to an actuation shaft 1428 and a distal actuator 1430.

[0189] In some embodiments, the distal end of the tool 1414 has two "fingers" 1432a / 1432b interconnected at a pivot 1434. In some embodiments, when the spring 1426 is actuated, it moves the shaft 1428 up and down, which causes the distal actuator 1430 to move the two "fingers" 1432a / 1432b relative to the pivot 1434, and this movement translates to opening and closing the two "fingers" 1432a / 1432b, thereby actuating the two fingers.

[0190] 14F and 14G show another example of how the "scissor mechanism" is activated. In some embodiments, the "scissor mechanism" includes an actuation shaft 1436 (shown only in FIG. 14F). In some embodiments, the "scissor mechanism" includes two "fingers" 1438a / 1438b interconnected by a pivot 1440, each with a bearing 1446a / 1446b. In some embodiments, there is an optional guide pin 1442 configured to move the two "fingers" 1438a / 1438b along a predetermined axis. In some embodiments, there is an optional spring 1444 (shown only in FIG. 14F) disposed between the two "fingers" 1438a / 1438b, which provides an opening force for the two "fingers" 1438a / 1438b, such that the "fingers" 1438a / 1438b are spaced apart by the spring 1444 when the actuation shaft is not actuated.

[0191] In some embodiments, actuation of the actuation shaft 1436 causes the actuation shaft 1436 to lower or raise. In some embodiments, lowering the actuation shaft 1436 pushes the two bearings 1446a / 1446b sideways, thereby closing the two "fingers" 1438a / 1438b (against the force provided by the spring 1444). In some embodiments, raising the actuation shaft 1436 causes the spring 1444 to push the two "fingers" 1438a / 1438b sideways, thereby opening the tool 1414. In some embodiments, the movement of the two "fingers" is an angular and / or circular movement that is different from a translational movement.

[0192] FIG. 14E illustrates an exemplary tool 1414 with an angled gripping tip 1446, and FIGS. 14F and 14G illustrate an exemplary tool 1414 with a parallel gripping tip 1448.

[0193] [Example of sensor mechanism] In some embodiments, the two "fingers" and / or sensors (e.g., 1418 and / or 1410) are configured to detect unexpected contact between the end effector and the environment, providing the system with anti-collision measures to avoid damage to the wiring system and / or panel. For example, if the sensors detect unexpected contact of the fingers (or other parts of the wiring end effector and / or arm) during the wiring process, the system includes instructions to stop the wiring operation. In some embodiments, the system optionally includes instructions to activate another wiring arm in place of the arm originally used.

[0194] As another example, if the wires become tangled during the wiring process, for example, the sensor detects the "unexpected" resistance and stops the wiring process to avoid damage to the system and / or the object being wired. In some embodiments, optionally, a tool is designed to be inserted between the wires and / or to manipulate the wires using two fingers and / or to open up space between the wires. Alternatively, the movement of the end effector and / or arm is configured to perform one or more movements to untangle the wires. In some embodiments, the system includes dedicated sensors configured to measure forces and moments during the untangling process.

[0195] In some embodiments, specialized "compliant tools," such as rubber fingers and / or spring fingers, are used to trial (or "dry run") wiring cycles (e.g., accessibility of components, ports, and locations in the process before performing the actual wiring cycle). In some embodiments, a potential advantage of this is that it allows new panel assembly sequences to be tested without damaging the system and tools.

[0196] [Simulation example] In some embodiments, analysis is performed using, for example, simulation and / or CAD analysis and / or vision analysis to determine the tools to use for a particular wiring process.

[0197] [Calibration process example] In some embodiments, a calibration process is performed on one or more tools to calculate the forces and moments acting on them. In some embodiments, external force / moment gauges are used for the calibration, which can take into account the geometry, sensor parameters, and position of the tool.

[0198] [Exemplary Method] Reference is now made to FIG. 15, which illustrates a flowchart of an example verification method, according to some embodiments of the present invention. In some embodiments, the system receives new wiring process data 1502 (an example wiring process is shown in FIG. 20B). In some embodiments, the system evaluates 1504 whether the received data has been verified. In some embodiments, if the answer is "no," the system initiates 1506 a verification process, such as the type of tool to use, possible wire routes, calculations of force application to system components, collision evaluation, insertion process, etc.

[0199] In some embodiments, the validation process is performed using simulation and / or analysis and / or dry runs, etc. In some embodiments, if the answer is "YES," the system begins a first operation (i) 1508. In some embodiments, the system selects an appropriate tool for the operation (1510). In some embodiments, the system selects an appropriate drill bit (optional) if necessary (1512). In some embodiments, the system takes one end of the wire as described in operation (i) and inserts it into component A (1514).

[0200] In some embodiments, the system routes the wire along the device (1516). In some embodiments, the system inserts the second end of the wire into component B as described in operation (i) (1518). In some embodiments, this example process is repeated until all operations have been performed. In some embodiments, once all operations have been performed, the wiring process is finished.

[0201] Optionally, after all wires have been processed, a QA cycle can be performed, optionally using a QA tool for this process.

[0202] 16, which illustrates a flowchart of a wiring method with an example wiring end effector module 208 having interchangeable tools, according to some embodiments of the present invention. In some embodiments, the system couples 1602 an appropriate tool to the wiring end effector module 208. In some embodiments, the appropriate tool is selected according to information received from the system and / or from real-time sensed information, for example, from information obtained from one or more cameras and / or digital sensors.

[0203] In some embodiments, the elongate extension grips the wire by applying a radial force to the wire (1604). In some embodiments, the force applied to the wire is between about 5 N and about 15 N, optionally between about 7 N and about 20 N, optionally between about 8 N and about 25 N, e.g., about 8 N, about 10 N, about 12 N. In some embodiments, the resolution of any of the above forces is about 1 N. In some embodiments, the effector module approximates the wire to the connector by applying an axial force (1606).

[0204] In some embodiments, the force applied to the wire is between about 5 N and about 15 N, optionally between about 7 N and about 20 N, optionally between about 8 N and about 25 N, e.g., about 8 N, about 10 N, about 12 N. In some embodiments, the resolution of any of the above forces is about 1 N. In some embodiments, the wire is then inserted (1608) into a hole in a connector of the component. In some embodiments, the system senses (1610) the resistance on the wire by the fact that the wire has reached the end of the hole in the connector.

[0205] In some embodiments, the system then secures the wire within the component's connector (1612) (see above method for securing a wire within a connector). In some embodiments, the system then pulls back the wire by gently applying an opposing axial force while sensing resistance from the grip sensor to assess a secure connection of the wire within the connector (1614). In some embodiments, the system slightly reduces the radial force on the wire while continuing to hold it (1616).

[0206] In some embodiments, if the wire insertion was the last wire to be connected to a component in the electrical cabinet, the method ends. In some embodiments, the system allows the wire (still held by the elongated extension) to slide into the elongated extension without releasing the wire (1618) while moving the mechanical arm away from the connector. In some embodiments, the system continues the wiring process as described elsewhere (1620).

[0207] 17A and 17B, a flowchart of an exemplary wiring method using an exemplary wiring end effector module when the wire includes a ferrule is shown, according to some embodiments of the present invention. In some embodiments, the system couples 1702 an appropriate tool to the wiring end effector module 208. In some embodiments, the appropriate tool is selected based on information received from the system and / or real-time sensed information, such as information from one or more cameras and / or digital sensors configured to identify the wire being used.

[0208] In some embodiments, the extension grips the wire by applying a radial force to the ferrule (1704). In some embodiments, the force applied to the ferrule is between about 3 N and about 110 N, optionally between about 7 N and about 20 N, optionally between about 8 N and about 25 N, e.g., about 8 N, about 10 N, or about 12 N. In some embodiments, the resolution of any of the above forces is about 0.5 N.

[0209] In some embodiments, the effector module approximates the ferrule to the connector by applying an axial force (1706). In some embodiments, the force applied to the wire is between about 3 N and about 15 N, optionally between about 7 N and about 20 N, optionally between about 8 N and about 25 N, e.g., about 8 N, about 10 N, about 12 N. In some embodiments, the resolution of any of the above forces is about 0.25 N. In some embodiments, the ferrule is then partially inserted (1708) into the hole of the component connector.

[0210] In some embodiments, optionally, the system partially closes a locking mechanism in the electrical terminal connector to hold the ferrule in place (1710). In some embodiments, the wire with the ferrule is held in place (1712). In some embodiments, this is performed by one or more additional elements disclosed above. In some embodiments, the extension is actuated to release the ferrule (1714). In some embodiments, the device then moves back along the wire (1716). In some embodiments, the extension re-gripped the wire itself (1718). In some embodiments, optionally, the system opens a previously partially closed locking mechanism of the electrical terminal connector (1720).

[0211] The flowchart continues in FIG. 17B after the letter A. In some embodiments, the system then applies an axial force to the ferrule, which has been fully inserted into the electrical terminal connector (1722). 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 (1724). In some embodiments, the system then secures the wire within the component's connector (1726) (see above method for securing a wire within a connector).

[0212] In some embodiments, the system then pulls back the wire by gently applying an opposing axial force while sensing resistance from the grip sensor to assess a solid connection of the wire within the connector (1728). In some embodiments, the system continues to hold the wire while slightly reducing the radial force on the wire (1730).

[0213] In some embodiments, if the wire insertion was the last wire to be connected to a component in the electrical panel, the method ends. 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 (1732). In some embodiments, the system continues the wiring process as described elsewhere (1734).

[0214] In some embodiments, parameters sensed by one or more sensors, either in the extension, gimbal block, or elsewhere in the system, such as forces, thresholds, and motion values ​​associated with the wire and the insertion process, are stored in a database.

[0215] [Example of wire management held by two wire arm modules, each optionally having a wire end effector module with interchangeable tools] In some embodiments, when two wiring arm modules hold wires, the system includes instructions for selecting an appropriate tool to hold the wire in a specific manner. An example is a specialized wire gripping tool for holding wires of a specific diameter in a specific position relative to an electrical cabinet. Another example is for the appropriate tool held by the two wiring arm modules to hold the wire while maintaining a specific tension between two points on the wire. In some embodiments, during the wiring planning process, each arm module is prepared and provided with a set of instructions including a list of required tools and when to use them.

[0216] In some embodiments, this is done to allow the robotic arms to operate potentially autonomously and without damaging each other, the electrical cabinet, the wires, and / or without the wires becoming tangled during the wiring process. In some embodiments, the tension on the wire is directional. For example, one mechanical arm holds one end of the wire with a specially selected tool, while another mechanical arm, also with a specially selected tool, holds the other end of the wire in an assigned direction within the electrical cabinet, optionally above a duct / DIN, while maintaining tension.

[0217] In some embodiments, the wire holding and tensioning functions are interchangeable between the two mechanical arms, as long as each arm is equipped with the correct tool. For example, at the beginning of a wiring operation, a first mechanical arm holds the wire and prevents it from moving, while a second mechanical arm slides the wire toward the location where it will be allocated. When the second arm reaches its desired location on the electrical cabinet, it stops, and the first arm releases the wire and moves to the location where the second mechanical arm is located 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 and moves it toward the location in the electrical cabinet where it will be positioned. In some embodiments, the mechanical arms can swap tools in the wiring end effector module 208 when swapping roles, if necessary.

[0218] In some embodiments, during the wiring process, one of the two arms slides on the wire as it is laid down on the duct / DIN, as described above when describing when the wiring end effector module 208 reduces the radial force on the wire, allowing the wire to slide while the mechanical arm is moving (see FIGS. 5B-5F and 15), for example, as also described in FIGS.

[0219] In some embodiments, a distance between the two wiring arms is maintained. In some embodiments, the distance is optionally adjusted during placement of the cable relative to the cable's route in the duct(s). In some embodiments, the distance between the arms optionally provides clearance from components located on the substrate. In some embodiments, the movement of the arms slows down or stops when the tension exceeds a threshold, for example, 15% above the desired tension and / or a predetermined threshold. In some embodiments, the threshold is set according to the wiring arm's capacity, the wire type, and any combination thereof. In some embodiments, the system monitors the distance between the arms and maintains a constant distance between the wiring arms. In some embodiments, the movement of the arms is adjusted or stopped when the distance between the arms exceeds a predetermined distance.

[0220] In some embodiments, if the system senses that the tension level in the wire and / or the distance between the arms is out of tolerance and / or is above or below a predetermined value, for example, ±20% of the predetermined / tolerance value, the wiring end effector releases the wire to avoid potential damage to the arms and / or panel / component.

[0221] In some embodiments, a vision system is used to validate the process before the wire is placed into the duct.

[0222] In some embodiments, the movement of two wiring arms for wiring a cabinet, such as (not an exhaustive list) movement of one arm relative to the other, movement of the arm relative to the cabinet, movement of the arm relative to the wires, movement of the arm relative to the wires and the wiring routing blueprints for the wires in the panel, and each of the above in relation to the dedicated interchangeable tools used during the wiring process, requires a high level of synchronization and precision in the movement of the arms at multiple levels and in the different tools used by the arms.

[0223] In some embodiments, an example of dual-arm coordination during a wire routing operation includes a first arm leading during routing, meaning that this arm inserts the end of the wire into an associated terminal connector in a component, and a second arm following and supporting the first arm during the routing process. In some embodiments, the leading wiring arm can become the support arm during the wiring process, and vice versa. In some embodiments, the support arm keeps the wire at a constant tension relative to the leading wire arm by maintaining a constant force (e.g., 2N, 4N, 8N) on the wire during the wiring process.

[0224] In some embodiments, during the wiring process, the support arms keep a portion of the wire under tension, e.g., the portion of the wire held between the two wiring arms, while leaving other portions untensioned (the wire sags and / or hangs behind the wire end effector). In some embodiments, the slack length is about 10% to about 30% of the total length of the wire being wired. Optionally, it is about 5% to about 40% of the total length of the wire being wired. Optionally, it is about 1% to about 50% of the total length of the wire being wired. For example, it is 15%, 20%, or 25% of the total length of the wire being wired.

[0225] In some embodiments, during the routing process, the slack wire is held above the plane on which the panel's components are located (if the routing is performed from above on horizontally oriented panels, see e.g., FIG. 4) and / or spaced from the plane on which the panel's components are located (if the routing is performed from the side on vertically oriented panels, see e.g., FIG. 3). In some embodiments, the second arm is kept a fixed distance behind the first arm as the leading arm moves toward the insertion point and guides the wire along the path drawn on the blueprint on the panel.

[0226] In some embodiments, as the leading arm moves towards the insertion point and guides the wire along the blueprinted path on the panel, the second arm is maintained in a position relative 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 waits on the other side of the hole to capture the end of the wire, thereby also becoming the leading wiring arm.

[0227] In some embodiments, the position of the second arm is set relative to the duct path and routing direction as the wire may be placed in the duct or passed through the clip. In some embodiments, if the duct is straight, the second arm is positioned at a duct location far from the component being routed. In some embodiments, the second arm is used to facilitate twisting of the wire, for example, to facilitate bending of the wire within a panel. In some embodiments, optionally, if a bend in the duct path is expected, the second arm is positioned above this location to facilitate twisting of the wire.

[0228] In some embodiments, while positioning the wire at a location where the wire direction changes, for example at a corner of a duct, excess 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 while changing direction at the required point in the path without pulling and / or distorting the wire.

[0229] In some embodiments, the wiring process includes plugging a first end of a wire into a terminal connector on a component inside the cabinet, and then directing the cable along a blueprinted path inside the cabinet to a second component inside the cabinet where the other end of the wire connects to a second terminal connector in the second component. In some embodiments, once the first end of the wire is plugged into the first component, e.g., by a first arm, the second arm becomes a leading arm and directs the wire toward the second component, and the first arm becomes a supporting arm.

[0230] In some embodiments, the support arm performs one or more of the following actions: Secure the wire in the duct (optionally using other tools, e.g., passive fingers, staplers, gluers, and / or latching elements, or may be used to place a plastic retaining strip ("bridge") that clears the way for the leading arm; Validate the routing process using one or more sensors (e.g., cameras, force sensors, laser line sensors, and / or proximity sensors).

[0231] In some embodiments, a safety zone is defined, for example above the component level (if the wiring runs from above on horizontally oriented panels, see e.g., FIG. 16) and / or spaced from the plane on which the panel's components are located (if the wiring runs from the side on vertically oriented panels, see e.g., FIG. 3), and the support arm with the wire is operated within the safety zone. In some embodiments, the panel is divided into multiple local safety zones, optionally with different safety heights.

[0232] In some embodiments, as described above, the wiring arms optionally include wire attachment elements (e.g., glue, adhesive tape, staples) actuated by one or more dedicated devices to provide a means for securing and / or affixing the wires to specific locations within the panel and / or duct. In some embodiments, as described elsewhere herein, the leading arm guides the distal end of the wire to its next point within the panel, while the support arm slides along the wire, positioning it in place along its path on the panel.

[0233] In some embodiments where multiple wires are being placed in the same duct, the position of the manipulated wire being held is relative to the wire already placed, e.g., if the center of the duct is occupied by another wire, the support arm will position the currently placed wire to one side of the duct and / or move it closer. In some embodiments, the software takes into account the load on the duct and can optionally add length to the wire to compensate for the additional distance required due to the load of the wire within the duct, e.g., adding 1%, 2%, or 5% to the length of the wire.

[0234] [Example of optimization features of the autorouting process] In some embodiments, the system comprises one or more features configured to optimize the autorouting process performed by the exemplary horizontal / vertical autorouting system.

[0235] [Cartridge for wasted wire during the wiring process] In some embodiments, the support wiring arm supports the operations performed by the leading wiring arm while the leading wiring arm positions the wire along the planned path within the cabinet, as described above. In some embodiments, one of these support operations is holding the remainder of the wire that the leading wiring arm is "trailing" while moving the end of the wire through the wiring path.

[0236] In some embodiments, the wiring arms optionally include dedicated cartridges in which waste wire is wound and / or held if the particular wire arm functions as a support wiring arm. In some embodiments, both arms optionally include dedicated cartridges, as the leading and supporting roles may change during the wiring process.

[0237] In some embodiments, the wire held in the dedicated cartridge is released as needed during the wiring process, for example if the arm movement requires a lot of wasted wire, taking into account ducts and / or obstacles in the wiring path. In some embodiments, a potential advantage of having a dedicated cartridge is that long lengths of wire remain housed during the wiring process, potentially avoiding wasted wire from causing damage or becoming tangled during the wiring process.

[0238] [Example of removing obstacles using a support wiring arm] In some embodiments, if and during the wiring process, the wires positioned in the cabinet by the leading wiring arm may become tangled and / or may not be correctly positioned at the desired location along the path, the system is configured to activate the support wiring arm and perform actions to resolve these issues. For example, the support wiring arm may move obstacles (e.g., other wires already positioned in the cabinet) away from the wire being positioned, optionally using a specialized tool (e.g., tweezers, a long, thin rod) that allows it to interact with the other wires without damaging them.

[0239] In some embodiments, optionally, the support wiring arms do not hold the wire in position while the obstacle is being removed. In some embodiments, optionally, the wire is routed with two arms around the obstacle. In some embodiments, instead, a new path is calculated that detours around the obstacle.

[0240] Use one wiring arm (if possible) In some embodiments, the system is not obligated 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, 5 cm), the system is configured to allow one wiring arm to perform the entire wiring process, leaving the second arm to perform other tasks related to the entire wiring process of the cabinet.

[0241] In some embodiments, optionally for short wires, the wiring arm anchors one end of the wire within the object / component, then slides along the wire (possibly "feeling" the sliding motion) to the other end, and then inserts the other end into the required location. In some embodiments, optionally after the initial insertion, the arm releases the wire and re-grabs the wire at the other end, optionally with the assistance of a sensor such as a vision camera.

[0242] [Using grip and sliding during the wiring process] In some embodiments, the system utilizes its "grab and slide" functionality to route the wire along a path outlined in the blueprint. For example, a routing arm can hold the wire on top of the surface where it needs to be positioned and slowly move along the wire while positioning it within the desired path (the "slide" component of the "grab and slide" functionality).

[0243] [Example of circuit breaker operation] In some embodiments, the wire end effector is configured to actuate, e.g., move up / down and / or push, the molded case circuit breaker within the panel using a dedicated interchangeable tool. In some embodiments, actuation is performed using an extension. In some embodiments, actuation is performed using a dedicated actuator. In some embodiments, switching the component on / off performs a specific test, such as, for example, a continuity test, a load test, a logic test (of the circuit logic), etc.

[0244] [Complex Wire Usage] In some embodiments, as described above, the system is configured to manipulate not only single wires but also wires containing one or more splits therein to provide multi-wire and / or harnesses. In some embodiments, for example, wires with a three-ended T-shaped harness, the support arm holds the wire in position where the split is provided, and the leading arm inserts one end of the wire into a component and then inserts the second end of the wire into a second component.

[0245] [Example of system use for wire harnesses inside cabinets] In some embodiments, the extension of the end effector is configured to hold a wire head that needs to be plugged into a component. For example, a network cable includes a specialized 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 specialized component in a cabinet. In some embodiments, the system includes information about the sensory feedback, e.g., force, torque, and visual feedback, that is recorded when connecting these types of wire heads.

[0246] 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, a locking actuator is used to secure the wire head in place, for example, by tightening the screws of a connector within the component. In some embodiments, a dual push action (i.e., push, release, and re-grasp) is used to insert the wire head.

[0247] [Options for splitting work in the timeline] In some embodiments, the system is configured to perform part of an operation, stop, perform another operation, and then select and finish the previous operation. For example, connect one end of a wire to one connector, position the wire along a path drawn on a blueprint, release the wire, perform another operation, and then return to the wire where it was previously left and continue positioning and / or connecting it to the connector. In some embodiments, re-grasping the wire is done using a vision system and / or by going to a known location (component, clip, corner) and sliding along the wire to its end.

[0248] [Example of giving multiple degrees of freedom to a wire end effector] In some embodiments, the wire end effector is provided with multiple degrees of freedom (DOF) to enable it to overcome obstacles and / or wire congestion. In some embodiments, the wire end effector or manipulating arm is provided with six degrees of freedom: three rotations and three translations about each vertical axis. In some embodiments, the wire end effector is provided with seven or more degrees of freedom. In some embodiments, a potential advantage of providing more than six degrees of freedom is that it may cause redundancy (or over-redundancy) issues in the software, but may also enable wire manipulation solutions when positioning the wire to overcome obstacles and / or in wire congestion situations.

[0249] [Example of wiring method using wiring arm module 206] 18 , a flowchart of an exemplary wiring method by the wiring arm module 206 is shown, according to some embodiments of the present invention. In some embodiments, the system receives information regarding the wire that needs to be used, the length of the wire, and the type of wire end required (1802). In some embodiments, a wire preparation module optionally prepares the wire, and in other embodiments, a wire ready for use is provided (1804). In some embodiments, a specialized tool is coupled to the end effector (1806). In some embodiments, the specialized tool is selected depending on the wire / cable that needs to be routed.

[0250] In some embodiments, the first end of the wire is picked up by the wiring arm module (1808). In some embodiments, the first end of the wire is manipulated to a location within the electrical cabinet (1810). In some embodiments, the wiring arm module 206 performs a validation check (1812) by inserting the first end of the wire into a terminal connector of the first component, locking the wire into the terminal block, and "feeling" the elongated extension 1006 / 1008 slipping, for example, by pulling back slightly on the wire rather than increasing force. In some embodiments, the second end of the wire is picked up by the wiring arm module (1814).

[0251] In some embodiments, the second end of the wire is manipulated 1816 to a location within the electrical cabinet. In some embodiments, manipulating the second end of the wire includes routing the wire from the location where the first end of the wire was inserted through the wire channel / track until the second end of the wire reaches that location. In some embodiments, the two wire arm modules work in concert to insert a wire through a channel / track, similar to how a human would do 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 while the other arm positions the wire in / through the channel / track, or, for example, when a wire needs to be threaded through an orifice, one arm holds the wire on one side of the orifice, threads the end of the wire through the orifice, and the other arm picks up the end of the wire from the other side of the orifice. The above examples are merely illustrative and in no way limiting of the present invention.

[0252] In some embodiments, the wiring arm module 206 plugs the second end of the wire into a connector on the second component, locks the wire into the terminal block, and performs a validation check (1818). In some embodiments, the system then evaluates whether there are any other wires required for the job (1820). 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 ends the job (1822).

[0253] [Data flow and operation examples] 19, a schematic diagram of an exemplary data flow and operation of an automated wiring system is shown, according to some embodiments of the present invention. In some embodiments, a user begins by virtually drawing a blueprint for an electrical cabinet (1902). In some embodiments, the user runs a simulation in specialized software (1904). In some embodiments, the blueprint is optionally optimized taking into account the results of the simulation (1906). In some embodiments, further simulations are run until the best blueprint is achieved. In some embodiments, before continuing, the system performs a final evaluation to see if the blueprinting phase is complete (1908). In some embodiments, if the answer is "no," the system returns to the blueprinting phase. In some embodiments, if the answer is "yes," the system creates an electrical schematic adapted to be shared with other platforms, the system creates a mechanical drawing of the electrical panel adapted to be shared with other platforms, and the system creates a bill of materials (BOM) for the assembly of the electrical cabinet (1910).

[0254] In some embodiments, at this point, the system generates 1911 a wire routing sequence based on the electrical schematic and the mechanical drawing. In some embodiments, generating the wire routing sequence includes virtually generating a set of possible sequences for inserting wires into the electrical cabinet, modifying the tools used during the wiring process, and evaluating problems that may occur during the actual wiring of the electrical cabinet, as described elsewhere herein. In some embodiments, the system optionally runs a simulation to optimize the wire routing sequence, optionally according to the determined parameters.

[0255] In some embodiments, the operations described above include continuous data exchange between the server and the computer of the user designing the electrical circuit (1912). In some embodiments, once everything is ready for assembly, the electrical cabinet is assembled in the automated electrical distribution unit / system 106 according to the final version of the blueprint (1914). In some embodiments, during assembly, the automated electrical distribution unit / system 106 communicates with the server for continuous monitoring of performance (1916).

[0256] [Example of a single-arm system] In some embodiments, the system includes a single mechanical arm configured to perform all automated operations of the wiring process. For example, a pre-cut wire ready for wiring is held by the mechanical arm on one side and reeled in on a winch on the other side, which releases the wire as needed. In some embodiments, the winch with the wire is provided directly from the wire preparation module to the mechanical arm.

[0257] Various embodiments and aspects of the present invention as described above and as claimed in the claims section below find experimental support in the following exemplary embodiments.

[0258] Illustrative Embodiments Reference will now be made to the following exemplary embodiments, which together with the above description illustrate some embodiments of the present invention in a non-limiting fashion.

[0259] 20A-20B, there is shown a schematic diagram of a two automated mechanical arm wiring process according to some embodiments of the present invention.

[0260] FIG. 20A shows a schematic diagram of two automated mechanical arms 2002 / 2004. In the following description, one automated mechanical arm will be referred to as arm 1 2002 and the other automated mechanical arm will be referred to as arm 2 2004. Also shown in FIG. 20A is a schematic diagram of an electrical panel 2006 that requires wiring. FIG. 20B shows the schematic diagram of the electrical panel 2006 in more detail. The exemplary electrical panel 2006 includes five ducts 2008-1 / 5. The exemplary electrical panel further includes multiple components, and in the present example, component A and component B require wires to connect between them.

[0261] Also marked in Figure 20B are circled reference points 1 through 8 for the following discussion.

[0262] As discussed above, in the following example, a wire needs to be placed between component A and component B. For this example, it has been determined that the selected path from component A to component B is by extending the wire, which is connected to component A, from reference point 1 to reference point 2, and continuing to reference point 3 and entering duct 2008-3. The wire then needs to bend within duct 2008-3 to reference point 4 and extend into duct 2008-5. The wire then needs to bend within duct 2008-5 to reference point 5. The wire then needs to bend within duct 2008-4 to reference point 6. The wire then exits duct 2008-4 at reference point 7 and continues to reference point 8 to be inserted into component B.

[0263] The following table summarizes the actions of Arm 1 2002 and Arm 2 2004 when placing a wire from Reference Point 1 to Reference Point 8.

[0264] [Table 1]

[0265] 21 , a graph illustrating exemplary phases of wire insertion into a component's electrical terminal connector as identified by sensors in the gripper, according to some embodiments of the present invention. In some embodiments, as further disclosed above, the system is configured to identify different phases of wire insertion into a component's electrical terminal connector. The graph in FIG. 21 shows the force sensed by sensors on finger extensions 910 a and 910 b of gripper 1308 on a held wire. In some embodiments, the phases are as follows:

[0266] Phase A: Advance Toward the Component's Electrical Terminal Connector. In some embodiments, during this phase, the wire is held by the gripper 1308, which advances toward the component's electrical terminal connector. In some embodiments, initially, the same force is sensed as if the wire had not encountered any obstructions. In some embodiments, at some point, the wire contacts the component's electrical terminal connector, and the sensor begins to sense an increase in the sensed force. Once a peak is reached, the system transitions to the next phase. In some embodiments, the peak may depend on, and be optionally set based on, the type of wire and / or the type of electrical terminal connector. In some embodiments, the relationship between wire type, component connector type, and "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 learning data.

[0267] Phase B: Retraction from the component's electrical terminal connector. In some embodiments, once a peak is reached, the gripper 1308 begins to retract, still holding the wire but without actually pulling on it. In some embodiments, as shown in the graph, the sensed force decreases significantly as the gripper releases its grip.

[0268] Phase C: Retract wire from component's electrical terminal connector while pulling. In some embodiments, the gripper gently holds the wire while continuing to retract from the component's electrical terminal connector to assess proper connection between the wire and the component's electrical terminal connector. In some embodiments, two things can happen at this point: 1. The wire is properly connected and there is no motion that would cause the gripper to slip on the connected wire, or 2. The wire is not properly connected and is pulled from the electrical terminal connector. In some embodiments, values ​​are learned and / or adjusted after each trial, as described above.

[0269] In some embodiments, different types of electrical terminal connectors and different types of wire are characterized by different forces sensed by the gripper, hi some embodiments, the system comprises a database in which different combinations of different types of electrical terminal connectors and different types of wire are stored, and according to input provided by a user, the system actuates the gripper accordingly.

[0270] 22A-22C, three different examples of the force sensed by the gripper in three different scenarios are shown, according to some embodiments of the present invention. Figure 22A shows an example of what the sensor sensed during gripper retraction, where no wire was connected to the component's electrical terminal connector at all. In this case, the wire does not resist the gripper pull, so the sensed force does not increase.

[0271] 22B shows an example of what the sensor senses during gripper retraction, where the wire was not properly connected to the component's electrical terminal connector. In this case, the gripper first begins to retract until the wire resists the pull, which translates to an increase in the sensed force. At some point, the wire becomes dislodged from the component's electrical terminal connector because it is not properly connected, as evidenced by a sudden decrease in the sensed force, which then returns to the same level as the beginning.

[0272] FIG. 22C shows an example of what the sensor senses during gripper retraction, where the wire has been properly connected to the component's electrical terminal connector. In this case, the gripper initially begins to retract until the wire resists the pull, which translates to an increase in sensed force. At some point, with the wire properly connected, the gripper begins to slip on the wire, evidenced by a decrease in the sensed force on the gripper at the end of the graph.

[0273] Referring now to FIG. 23 , several test experiments characterizing an exemplary scenario are shown, according to some embodiments of the present invention. As previously disclosed, initially, the input from the force sensor is steady as the gripper moves without resistance from the wire. Next, as the wire enters the component's electrical terminal connector, a spike occurs in the input from the sensor due to resistance between the wire and the connector. The device then begins to pull back on the wire to evaluate the connection between the wire and the component's electrical terminal connector. This portion is characterized by a sudden decrease in the input received from the sensor, as shown in FIG. 23 .

[0274] Next, various inputs are received from the sensor depending on the outcome of the connection between the wire and the electrical terminal connector. In Test 1, the wire came off the connector, as can be seen from the unchanged graph. In Test 2, the wire came off the connector while being pulled backward. In Test 3, the wire was fully connected to the connector, and the gripper slipped on the wire during retraction. In Test 4, the wire came off the connector while being pulled backward. The foregoing graphs are exemplary experiments provided to enable those skilled in the art to understand the present invention and are in no way limiting.

[0275] When used herein in reference to an amount or value, the term "about" means "within ±20% thereof." The terms "comprises," "comprising," "includes," "including," "has," "having," and their cognates mean "including but not limited to."

[0276] The term "consisting of" means "including and limited to." The term "consisting essentially of" means that a composition, method, or structure may include additional ingredients, steps, and / or parts, but only if the additional ingredients, steps, and / or parts do not materially alter the basic and novel characteristics of the claimed composition, method, or structure.

[0277] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. For example, the term "a compound" or "at least one compound" can include multiple compounds, including mixtures thereof.

[0278] Throughout this application, embodiments of the invention may be presented with reference to a range format. It should be understood that the description in range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all possible subranges as well as individual numerical values ​​within that range. For example, a description of a range such as "1 to 6" should be considered to have specifically disclosed subranges such as "1 to 3," "1 to 4," "1 to 5," "2 to 4," "2 to 6," "3 to 6," etc., as well as individual numerical values ​​within that range, e.g., 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

[0279] When a range of numerical values ​​is given herein (e.g., a set of numerical values ​​connected by "10-15," "10 to 15," or another such range designator), it is meant to include any number (fractional or integer) within the limits of the stated range, inclusive of the limits of the range, unless the context clearly dictates otherwise. The phrase "range / ranging / ranges between" a first designator and a second designator, and the phrase "range / ranging / ranges from" a first designator "to," "up to," "until," or "through" a second designator, are used interchangeably herein and are meant to include the first designator and the second designator, and all fractional and integer numbers therebetween.

[0280] Unless otherwise indicated, the numerical values ​​used herein and any numerical ranges based thereon are approximations within reasonable measurement precision and rounding error as understood by those skilled in the art. It is understood that certain features of the invention that are described for clarity in the context of separate embodiments can also be provided in combination in a single embodiment. Conversely, various features of the invention that are described for brevity in the context of a single embodiment can also be provided separately or in any suitable subcombination, or as suitable in any other described embodiment of the invention. Particular features described in the context of various embodiments should not be considered essential features of those embodiments, unless the embodiment cannot function without those elements.

[0281] While the present invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and broad scope of the appended claims.

[0282] It is the intention of the applicants (applicants) that all publications, patents, and patent applications mentioned herein be incorporated by reference in their entireties, as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference herein. Furthermore, citation or identification of any reference in this application should not be construed as an admission that such reference is available as prior art to the present invention. Section headings, if used, should not be construed as necessarily limiting. Additionally, any priority document(s) of this application are hereby incorporated by reference in their entireties.

Claims

1. 1. An end effector of a robotic wiring system, comprising: a wire holder with a first type of interchangeable tool; End effector.

2. the wire holder includes a first adapter configured to allow exchange of the first type of exchangeable tool; The end effector of claim 1 .

3. the first type of interchangeable tool is one or more of a wire gripping tool, a USB gripper, an RJ45 gripper, an HDMI gripper, a continuity test probe, and a USB data transfer tool; The end effector according to claim 1 or 2.

4. the first type of interchangeable tool comprises two elongated finger-like extensions; The end effector according to any one of claims 1 to 3.

5. The two elongated finger extensions are actuated using a "scissor-style" mechanism; The end effector of claim 4 .

6. The "scissor" mechanism provides angular movement to the two elongated finger extensions. The end effector of claim 5 .

7. the two elongated finger-like extensions are characterized by one or more actuation states including an open state, a semi-closed state, and a closed state; The end effector of claim 4 .

8. the wire holder includes a restraining actuator configured to maintain the first type of interchangeable tool in an actuated state during use of the end effector; The end effector according to any one of claims 1 to 7.

9. The two elongated finger-like extensions are characterized in that the distance between the two elongated finger-like extensions is about 2 mm to about 7 mm. The end effector of claim 4 .

10. The two elongated finger-like extensions are configured such that the distance between the two elongated finger-like extensions is sufficient to hold the required object. The end effector of claim 4 .

11. the two elongated finger extensions are configured to apply a force of about 1 N to about 20 N; The end effector of claim 4 .

12. the two elongated finger extensions are configured to grip wires having a diameter of about 0.5 mm to about 6.0 mm and larger diameter wires; The end effector of claim 4 .

13. each of the two elongated finger extensions comprises a distal end configured to hold one or more of a wire, a connector, a USB connector, an RJ45 connector, an HDMI connector, a cable, a tube, a fiber optic cable, and a fiber optic tube; The end effector of claim 4 .

14. the wire holder includes one or more first sensors configured to monitor an action performed by the wire holder; The end effector of claim 4 .

15. one of the one or more first sensors is at least one force sensor measuring force from one or more axes; The end effector of claim 14.

16. at least one sensor of the one or more first sensors is positioned on the end effector and is additionally configured to monitor the first type of interchangeable tool; The end effector of claim 14.

17. the end effector includes dedicated calibration information used by the one or more first sensors for each type of the first type of exchangeable tool; The end effector of claim 14.

18. one or more of the one or more first sensors is positioned on the first type of exchangeable tool; The end effector of claim 14.

19. the wire holder includes one or more first motors for moving the wire holder in one or more directions; An end effector according to any one of claims 1 to 18.

20. the wire holder includes one or more second sensors for monitoring movement of the wire holder; 20. The end effector of claim 19.

21. one of the one or more second sensors is at least one anti-collision sensor for monitoring external forces applied to one or more parts of the end effector during use; The end effector of claim 20.

22. the wire holder includes an exchangeable tool lock for locking the first type of exchangeable tool in place; An end effector according to any one of claims 1 to 21.

23. the first type of interchangeable tool comprises at least one identification mark; An end effector according to any one of claims 1 to 22.

24. the first type of interchangeable tool has a distal end that holds a component at an angle relative to an axis of the first type of interchangeable tool; An end effector according to any one of claims 1 to 23.

25. The angle ranges from about 0° to about 180°.

25. The end effector of claim 24.

26. the distance from the distal end of the first type of exchangeable tool to the first adapter is between about 10 mm and about 300 mm; The end effector of claim 2 .

27. the first type of interchangeable tool has a total width of about 1 mm to about 10 mm; An end effector according to any one of claims 1 to 26.

28. the end effector replaces the first type of exchangeable tool from a plurality of the first type of exchangeable tools arranged in a dedicated stand for the first type of exchangeable tool; An end effector according to any one of claims 1 to 27.

29. and further comprising a wire lock comprising a second type of interchangeable tool. An end effector according to any one of claims 1 to 28.

30. the second type of interchangeable tool is a power screwdriver configured to accept one or more interchangeable driver bits; 30. The end effector of claim 29.

31. the power screwdriver includes a second adapter configured to allow replacement of the one or more interchangeable driver bits; 31. The end effector of claim 30.

32. the second type of replaceable tool is a motorized depressor configured to depress a locking feature within the electrical connector terminal; 30. The end effector of claim 29.

33. the wire locking portion includes one or more third sensors that monitor the locking operation of the wire locking portion; 30. The end effector of claim 29.

34. one of the one or more third sensors is a torque sensor configured to monitor torque on a locking mechanism of the electrical terminal connector; 34. The end effector of claim 33.

35. the wire locking portion includes one or more second motors for moving the wire locking portion in one or more directions; 30. The end effector of claim 29.

36. the first type of interchangeable tool is configured to perform operations related to an automated wiring process; An end effector according to any one of claims 1 to 35.

37. the second type of interchangeable tool is configured to perform operations related to an automated wiring process; 30. The end effector of claim 29.

38. The operation is one or more of: gripping a wire, gripping a tube, gripping a cable, locking a wire, testing continuity, and transmitting data; 38. An end effector according to claim 36 or 37.

39. The first type of interchangeable tool is configured to fit into a tight space. An end effector according to any one of claims 1 to 38.

40. The second type of interchangeable tool is configured to fit into a narrow space.

30. The end effector of claim 29.

41. the first type of interchangeable tool is configured for use in a verification process; An end effector according to any one of claims 1 to 40.

42. the second type of interchangeable tool is configured for use in a verification process; 30. The end effector of claim 29.

43. the first type of interchangeable tool is configured for use in a quality assurance (QA) process; An end effector according to any one of claims 1 to 42.

44. the second type of interchangeable tool is configured for use in a quality assurance (QA) process; 30. The end effector of claim 29.

45. a single multi-sensor configured to monitor the process of all components of the end effector; An end effector according to any one of claims 1 to 44.

46. the calibration information is generated by one or more of testing, analysis, and simulation; The end effector of claim 16.

47. a. at least one robotic arm comprising the end effector of claim 1; b. a tool rest with a plurality of tools; A robot wiring system comprising:

48. 1. A method for performing a wiring process by an automatic wiring machine, comprising: a. receiving wiring information data including a plurality of operations; b) Picking up a dedicated tool for each of the plurality of tasks by the automatic wiring machine in accordance with the wiring information data; c) performing the work among the plurality of works in accordance with the wiring information data; the method including exchanging tools when a particular task among the plurality of tasks requires a tool different from the picked-up tool. method.

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