Automatic electrical wiring system and method

Abstract

One aspect of some embodiments of the present invention relates to an automatic electrical wiring system that includes a wire preparation module, at least one wiring arm module having a wiring end effector at a distal end thereof for manipulating a wire to be inserted into an object requiring electrical wiring, and circuitry that coordinates the operation of the wire preparation module and the at least one wiring arm module using at least one parameter related to the need for electrical wiring.

Description

[Technical Field]

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

[0002] This application is also related to a concurrently filed PCT patent application (Attorney Docket No. 90346) entitled "SYSTEMS AND METHODS FOR AUTOMATIC ELECTRICAL WIRING WITH ENDEFFECTOR," the contents of which are incorporated herein by reference in their entirety. [Background technology]

[0003] The present invention, in some embodiments thereof, relates to automated electrical wiring systems and methods, and more particularly, but not exclusively, to automated electrical wiring systems and methods for electrical cabinets.

[0004] The preparation and wiring of electrical cabinets involves a complex process of wire architecture design and difficult wiring tasks. The present invention discloses an automated electrical wiring system and method that potentially improves the creation and manufacturing of electrical cabinets. Summary of the Invention

[0005] 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.

[0006] Example 1.a. At least one wiring arm module having a wiring end effector at its distal end for holding and manipulating a wire; b. at least one sensor located within the wire end effector; c. A circuit comprising: i. receiving a command to perform an electrical wiring activity by using the at least one wiring arm module comprising the wiring end effector; ii. the circuitry that adjusts the operation of the at least one wiring arm module and the wiring end effector in consideration of a sensed property of the wire caused by the activity; Automated electrical wiring systems, including:

[0007] Example 2. The automated electrical wiring system of Example 1, wherein the at least one parameter is one or more of a condition of the wire, a deformation of the wire, a position of the wire, a force applied to the wire, a torque applied to the wire, and a type of connector within the object.

[0008] Example 3. The automated electrical wiring system of example 1, wherein the wiring end effector includes a wire holding element.

[0009] Example 4. The automated electrical wiring system of example 1, wherein the wire holding element comprises a wire clamping element including two extensions.

[0010] Example 5. The automated electrical wiring system of example 4, wherein the two extensions are two elongated extensions.

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

[0012] Example 7. The automated electrical wiring system of example 4, wherein the two extensions are coupled by a pneumatic mechanism.

[0013] Example 8. The automated electrical wiring system of Example 1, wherein the operation includes inserting the wire into a connector of an object requiring electrical wiring.

[0014] Example 9. The automated electrical wiring system of example 8, wherein the wire comprises a motor for movement along a receptacle axis of the connector within the object.

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

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

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

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

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

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

[0021] Example 16. The automated electrical wiring system of Example 1, wherein the circuitry receives the commands to perform electrical wiring activities from at least one design console.

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

[0023] Example 18. The automated electrical wiring system of Example 16, wherein the at least one design console includes software dedicated to creating electrical circuit design drawings.

[0024] Example 19. The automated electrical wiring system of Example 16, wherein the at least one design console communicates with at least one server.

[0025] Example 20. The automated electrical wiring system of Example 16, wherein the at least one design console includes software dedicated to the creation of mechanical drawings.

[0026] Example 21. The automated electrical wiring system of Example 16, wherein the at least one design console includes dedicated software for generating merged electrical circuit design drawings and mechanical drawings.

[0027] Example 22. An automated electrical wiring system as described in Example 16, wherein the at least one design console includes dedicated software for generating a wire routing sequence according to one or more of an electrical circuit design drawing and a mechanical drawing.

[0028] Example 23. The automated electrical wiring system of example 1, further comprising a monitoring system.

[0029] Example 24. An automated electrical wiring system as described in Example 23, wherein the monitoring system includes one or more cameras.

[0030] Example 25. An automated electrical wiring system as described in Example 23, wherein the monitoring system includes one or more sensors.

[0031] Example 26. An automated electrical wiring system as described in Example 23, wherein the monitoring system includes one or more force sensors.

[0032] Example 27. An automated electrical wiring system as described in Example 23, wherein the monitoring system includes one or more torque sensors.

[0033] Example 28. An automated electrical wiring system as described in Example 23, wherein the monitoring system includes one or more current sensors.

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

[0035] Example 30. The automated electrical wiring system of Example 1, wherein the at least one wiring arm module is mounted on a rail.

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

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

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

[0039] Example 34. The automated electrical wiring system of Example 1, wherein two wiring arm modules cooperate with each other during said manipulation of said wires.

[0040] Example 35. The automatic electrical wiring system of Example 34, wherein the two wiring arm modules during operation are spaced apart from each other to apply tension to the wires.

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

[0042] Example 37. An automatic electrical wiring system as described in Example 34, wherein during operation, one of the two wiring arm modules grips the wire and the other of the wiring arm modules slides over the wire to a desired position.

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

[0044] Example 39. An automatic electrical wiring system as described in Example 34, wherein the system is configured to monitor the movement of each of the two wiring arm modules.

[0045] Example 40. An automatic electrical wiring system as described in Example 39, wherein the movement is one or more of: movement of one of the two wiring arm modules relative to the other, movement of each of the two wiring arm modules relative to the connector, movement of each of the two wiring arm modules relative to the object, the distance between the two wiring arm modules, and the tension of the wire held between the two wiring arm modules.

[0046] Example 41. An automatic electrical wiring system as described in Example 40, wherein the system is configured to correct the movement when a certain predetermined value is sensed regarding the movement.

[0047] Example 42. The automated electrical wiring system of Example 1, further comprising a wire preparation module configured to prepare a wire to be inserted into an object requiring electrical wiring.

[0048] Example 43. An automatic electrical wiring system as described in Example 42, wherein the wire preparation module provides ready-to-use wire to the at least one wiring arm module.

[0049] Example 44. The automated electrical wiring system of Example 1, further comprising the object requiring electrical wiring.

[0050] Example 45. An automated electrical wiring system as described in Example 40, wherein the object is an electrical cabinet.

[0051] Example 46. An automated electrical wiring system as described in Example 42, wherein the electrical cabinet includes one or more smart components configured to assist with the electrical wiring.

[0052] Example 47. An automatic electrical wiring system as described in Example 43, wherein the one or more smart components are one or more of a smart wire, a smart duct, a latch, a holder, and a marker.

[0053] Example 48. A method for automatically connecting at least one wire to at least one connector in a component, comprising: a. automatically grasping a distal end of at least one wire with at least one wire holder; b. automatically moving the at least one wire holder to bring the distal end of the at least one wire closer to the at least one connector; c. automatically inserting the distal end of the at least one wire into the at least one connector; d. automatically evaluating whether said at least one wire is properly connected to said at least one connector; Including, The method further includes sensing at least one parameter of the at least one wire associated with the at least one connector during the automatically plugging and the automatically evaluating.

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

[0055] Example 50. The method described in Example 55, wherein the inserting is performed by moving the at least one wire holder.

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

[0057] Example 52. The method described in Example 55, wherein the inserting is performed by moving a robotic arm to which the at least one wire holder is attached.

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

[0059] Example 54. The method of Example 55, further comprising automatically locking the at least one wire with the at least one connector by activating at least one locking mechanism.

[0060] Example 55. The method of Example 55, wherein the automatically evaluating includes retracting the at least one wire from the at least one connector.

[0061] Example 56. The method of Example 62, wherein the evaluating includes sensing whether the at least one wire resists the retraction.

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

[0063] Example 58. The method described in Example 57, wherein the two wiring arm modules during the connection are spaced apart from each other to apply tension to the at least one wire.

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

[0065] Example 60. The method described in Example 58, wherein one of the two wiring arm modules during the connection grips the wire, and the other of the wiring arm modules slides over the wire to a desired position.

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

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

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

[0069] Example 64. The wiring method of Example 63, further comprising modifying the movement when a predetermined value is sensed regarding the movement.

[0070] Example 65.a. Wire delivery unit; b. at least one wiring arm module having a wiring end effector at a distal end thereof for manipulating a wire received by said wire delivery unit so as to be plugged into a connector in an object requiring electrical wiring; c. a circuit for adjusting the operation of the wire delivery unit and the at least one wiring arm module using at least one parameter related to the electrical wiring needs; Automated electrical wiring systems, including:

[0071] Example 66. An automatic electrical wiring system as described in Example 65, wherein the wire delivery unit is a wire preparation module for preparing a wire to be plugged into the connector in the object requiring electrical wiring.

[0072] Example 67. An automatic electrical wiring system as described in Example 65, wherein the wire delivery unit includes a prefabricated wire that is plugged into the connector in the object requiring the electrical wiring.

[0073] Example 68.a. A wire retaining element having two extensions; b. at least one sensor configured to monitor a force applied to at least one wire held by said wire holding element; and a wiring end effector.

[0074] Example 69. A wiring end effector as described in Example 68, wherein the two extension portions are two elongated extension portions.

[0075] Example 70. A wiring end effector as described in Example 68, wherein the at least one sensor is located within the wire holding element.

[0076] Example 71. A wiring end effector as described in Example 68, wherein the at least one sensor is located within the two extension portions.

[0077] Example 72. A wiring end effector as described in Example 68, further comprising a wire locking element including a connector locking mechanism actuator.

[0078] Example 73. A method for automatically wiring an object requiring electrical wiring, comprising: a. receiving an electrical wiring design drawing of the object requiring the electrical wiring and a wiring sequence according to the design drawing; b. Providing a plurality of wires; c. delivering the prepared wire to an automated wiring arm module; d. automatically wiring the prepared wires within the object requiring the electrical wiring according to the generated wire routing sequence; The method comprising:

[0079] Example 74. A method for automatically wiring an object requiring electrical wiring, comprising: a. drawing a blueprint of the electrical wiring of the object requiring the electrical wiring; b. automatically generating a wire routing sequence according to the design drawing; c. Providing a plurality of wires; d. delivering the prepared wire to an automated wiring arm module; e. automatically wiring the prepared wires within the object requiring the electrical wiring according to the generated wire routing sequence; The method comprising:

[0080] Example 75.a. At least one wiring arm module having a wiring end effector at its distal end for manipulating a wire to be inserted into a hole in a connector in a component; b. circuitry that adjusts the operation of the at least one wiring arm module and the wiring end effector using at least one parameter associated with the connector; c. one or more sensors configured to detect a parameter associated with the wire while being inserted into the hole of the connector by the wiring end effector; Automated electrical wiring systems, including:

[0081] Example 76.a. A wire retaining element having two extensions; b. a locking device comprising an electrical terminal connector locking mechanism actuator; a wiring end effector.

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

[0083] Example 78.a. Wire retention element with two extensions. b. a locking device comprising an electrical terminal connector locking mechanism actuator; c. a wire feeder configured to feed at least one wire into the wire holding element; a wiring end effector.

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

[0085] Example 80.a. A wire retaining element having two extensions; b. a camera configured to monitor the actuation of the wire retaining element; a wiring end effector.

[0086] Example 81. A wiring end effector as described in Example 80, further comprising a locking device including a connector locking mechanism actuator.

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

[0088] Example 83. A wiring end effector as described in Example 80, further comprising at least one sensor configured to monitor a force applied to at least one wire held by the wire holding element.

[0089] Example 84.a. A wire retaining element having two extensions; b. a wire cutter configured to cut a distal portion of the wire held by the wire holding element; a wiring end effector.

[0090] Example 85. A wiring end effector as described in Example 84, further comprising a camera configured to monitor the actuation of the wire holding element.

[0091] Example 86. A wiring end effector as described in Example 84, further comprising a locking device including a connector locking mechanism actuator.

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

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

[0094] Example 89. A method for drawing up a design drawing for automatic wiring of at least one object requiring electrical wiring in a design console of an automatic electrical wiring system, comprising: a. receiving rules relating to electrical and / or mechanical diagrams from at least one user; b. receiving the electrical schematics and / or the mechanical drawings at the design console; c. performing an automated check of said design according to said rules; d. merging the electrical schematic with the mechanical drawing to generate an original wiring design; e. Preparing the robot wiring blueprint; The method comprising:

[0095] Example 90. The method described in Example 89, wherein the rules are related to one or more standards, special requirements by a client, technical limitations, and personal rules inserted by the one or more users.

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

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

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

[0099] Example 94. The method of example 89, further comprising performing a second check on the underlying wiring design according to the rules.

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

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

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

[0103] Example 98. A method for placing a wire along a path by two robotic arms, comprising: a. holding a first end of the wire with a first robotic arm; b. placing the first end of the wire at a first location along the path; c. positioning the wire along the path by sliding a second robotic arm along the wire toward the first position; The method comprising:

[0104] Example 99. A method for automatically wiring a lighting unit by connecting at least one wire to at least one connector, comprising: a. automatically grasping the distal end of the wire with a wire holder; b. automatically moving the wire holder to bring the distal end of the wire closer to the connector; c. automatically inserting the distal end of the wire into the connector; d. automatically evaluating whether said at least one wire is properly connected to said at least one connector; Including, The method further includes sensing at least one parameter of the wire associated with the connector during the automatically plugging and the automatically evaluating.

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

[0106] Example 101. The method described in Example 99, wherein the inserting is performed by moving the wire holder.

[0107] Example 102. The method described in Example 99, wherein the inserting is performed by moving the connector.

[0108] Example 103. The method described in Example 99, wherein the inserting is performed by moving a robotic arm to which the wire holder is attached.

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

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

[0111] Example 106. The method described in Example 99, wherein the automatically evaluating includes retracting the at least one wire from the at least one connector.

[0112] Example 107. The method of Example 106, wherein the evaluating includes sensing whether the at least one wire resists the retraction.

[0113] Below is a further non-exclusive 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.

[0114] Example 1001.a. At least one wiring arm module having a wiring end effector at its distal end for manipulating the wire to be plugged into an object requiring electrical wiring; b. circuitry for regulating the operation of the wire preparation module and the at least one wiring arm module using at least one parameter related to the electrical wiring needs; Automated electrical wiring systems, including:

[0115] Example 1002. An automated electrical wiring system as described in Example 1001, further including a wire preparation module.

[0116] Example 1003. An automatic electrical wiring system as described in Example 1001 or Example 1002, wherein the wiring preparation module is configured to prepare a wire to be inserted into an object requiring electrical wiring.

[0117] Example 1004: An automatic electrical wiring system described in any one of Examples 1001 to 1003, wherein the wire preparation module includes a plurality of wire stocks.

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

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

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

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

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

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

[0124] Example 1011. An automatic electrical wiring system described in any one of Examples 1001 to 1010, wherein at least one wiring arm module includes multiple joints.

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

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

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

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

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

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

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

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

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

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

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

[0136] Example 1023. An automatic electrical wiring system described in any one of Examples 1001 to 1022, wherein the wire preparation module provides ready-to-use wire to the at least one wiring arm module.

[0137] Example 1024. An automatic electrical wiring system described in any one of Examples 1001 to 1023, wherein the wire preparation module provides multi-end harness wires ready for use.

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

[0139] Example 1026: An automated electrical wiring system described in any one of Examples 1001 to 1025, wherein the at least one design console is one or more of an electronic device, a computer, a tablet, a mobile phone, and a server.

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

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

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

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

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

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

[0146] Example 1033. An automatic electrical wiring system described in any one of Examples 1001 to 1032, further including a monitoring system.

[0147] Example 1034. An automatic electrical wiring system described in any one of Examples 1001 to 1033, wherein the monitoring system includes one or more cameras.

[0148] Example 1035. An automatic electrical wiring system described in any one of Examples 1001 to 1034, wherein the monitoring system includes one or more sensors.

[0149] Example 1036. An automatic electrical wiring system described in any one of Examples 1001 to 1035, wherein the monitoring system includes one or more force sensors.

[0150] Example 1037. An automatic electrical wiring system described in any one of Examples 1001 to 1036, wherein the monitoring system includes one or more torque sensors.

[0151] Example 1038. An automatic electrical wiring system described in any one of Examples 1001 to 1037, wherein the monitoring system includes one or more current sensors.

[0152] Example 1039. An automatic electrical wiring system described in any one of Examples 1001 to 1038, further including the object requiring electrical wiring.

[0153] Example 1040.a. Wire delivery unit; b. at least one wiring arm module having a wiring end effector at its distal end for manipulating the wire to be plugged into an object requiring electrical wiring; c. circuitry for regulating the operation of the wire preparation module and the at least one wiring arm module using at least one parameter related to the electrical wiring needs; Automated electrical wiring systems, including:

[0154] Example 1041. An automatic electrical wiring system as described in Example 1040, wherein the wire delivery unit is a wire preparation module for preparing a wire to be inserted into an object requiring electrical wiring.

[0155] Example 1042. An automated electrical wiring system as described in Example 1040, wherein the wire delivery unit includes a prefabricated wire that is inserted into the object requiring the electrical wiring.

[0156] Embodiment 1043.a. A wire retaining element having two elongated extensions; b. a wire locking element comprising a terminal block actuator; a wiring end effector.

[0157] Example 1044. A method of preparing electrical wire by an automated wire preparation machine including a plurality of wire stocks, one or more wire manipulators, at least one wire stripper module, a plurality of wire end connector attachment modules, at least one labeling module, and a wire cutter, comprising: a. picking a first end of a wire from the plurality of wire stocks with a first wire manipulator from the one or more wire manipulators; b. stripping the coating from the first end of the wire by moving the first end of the wire into the at least one stripper module to expose a wire core; c. releasing the length of wire as needed for the length of wire provided; d. pinching the wire at said desired length with a second wire manipulator from said one or more wire manipulators; e. creating a second end of the wire by moving the wire into the wire cutter; f. moving the second end of the wire into the at least one stripper module to strip the coating from the second end of the wire and expose a wire core; The method comprising:

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

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

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

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

[0162] Example 1049. A method for automatically wiring an object requiring electrical wiring, comprising: a. receiving an electrical wiring design drawing of the object requiring the electrical wiring and a wiring sequence according to the design drawing; b. Providing a plurality of wires; c. delivering the prepared wire to an automated wiring arm module; d. automatically wiring the prepared wires within the object requiring the electrical wiring according to the generated wire routing sequence; The method comprising:

[0163] Example 1050. A method for automatically wiring an object requiring electrical wiring, comprising: a. drawing a blueprint of the electrical wiring of the object requiring the electrical wiring; b. automatically generating a wire routing sequence according to the design drawing; c. Providing a plurality of wires; d. delivering the prepared wire to an automated wiring arm module; e. automatically wiring the prepared wires within the object requiring the electrical wiring according to the generated wire routing sequence; The method comprising:

[0164] 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 in the practice or testing 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.

[0165] As will be appreciated by those skilled in the art, some embodiments of the present invention may be embodied as a system, a method, or a 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, which may be 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.

[0166] For example, hardware for performing selected tasks according to some embodiments of the present invention may be implemented as a chip or circuit. As software, selected tasks according to some embodiments of the present invention may be implemented as a plurality of software instructions executed by a computer using any suitable operating system. In exemplary embodiments of the present invention, one or more tasks according to some exemplary embodiments of the 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. A display and / or a user input device, such as a keyboard or mouse, are also optionally provided.

[0167] Some embodiments of the present invention may utilize any combination of one or more computer-readable 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 electrically erasable programmable read-only memory (EEPROM 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.

[0168] 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.

[0169] The program code embodied on the computer-readable storage 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.

[0170] 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 Java, Smalltalk, C++, etc., and conventional procedural programming languages ​​such as 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).

[0171] 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. It will be understood that 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.

[0172] 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.

[0173] 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.

[0174] Some of the methods described herein are generally designed for use by a computer only and may not be suitable or practical to be performed entirely manually by a human expert. A human expert wishing to manually perform a similar task, such as plugging wires into sockets and / or designing the architecture of an electrical cabinet, may 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.

[0175] 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]

[0176] [Figure 1A] 1 is a schematic diagram of an exemplary automatic wiring system, in accordance with some embodiments of the present invention. [Figure 1B] 1 is a flowchart of an exemplary method for merging electrical schematics with mechanical schematics within and by a design console, according to some embodiments of the present invention. [Figure 2] FIG. 1 is a circuit diagram of an exemplary automatic wiring unit / system, according to some embodiments of the present invention. [Figure 3] FIG. 1 is a schematic diagram of an exemplary automatic wiring unit / system, according to some embodiments of the present invention. [Figure 4] FIG. 2 is a schematic diagram of an exemplary wire preparation module, according to some embodiments of the present invention. [Figure 5] 1A-B are schematic diagrams of an exemplary wire manipulator, according to some embodiments of the present invention. [Figure 6A] 1 is a flowchart of an exemplary wire preparation method, according to some embodiments of the present invention. [Figure 6B] 1 is a flowchart of an exemplary wire preparation method, according to some embodiments of the present invention. [Figure 6C] 1 is a flowchart of an exemplary wire preparation method, according to some embodiments of the present invention. [Figure 7A] 1 is an exemplary wiring arm module including multiple joints, according to some embodiments of the present invention. [Figure 7B1] 1 is a schematic diagram of an exemplary typical cycle of actions performed by a human when routing a wire into a connector. [Figure 7B2] 1 is a schematic diagram of an exemplary typical cycle of actions performed by a human when routing a wire into a connector. [Figure 7B3] 1 is a schematic diagram of an exemplary typical cycle of actions performed by a human when routing a wire into a connector. [Figure 7B4] 1 is a schematic diagram of an exemplary typical cycle of actions performed by a human when routing a wire into a connector. [Figure 7B5] 1 is a schematic diagram of an exemplary typical cycle of actions performed by a human when routing a wire into a connector. [Figure 8A] 1 is a schematic diagram of an exemplary wiring arm module, according to some embodiments of the present invention. [Figure 8B] 1 is a schematic diagram of an exemplary wiring arm module, according to some embodiments of the present invention. [Figure 9A] 1 is a schematic diagram of an exemplary wiring end effector module, according to some embodiments of the present invention. [Figure 9B] 1A-1C are schematic diagrams of components of a wire retention element, according to some embodiments of the present invention. [Figure 9C1] 10A-10C are schematic diagrams of sensors located on elongate extensions according to some embodiments of the present invention. [Figure 9C2]1A and 1B are schematic diagrams of exemplary gimbal blocks with extensions coupled thereto, according to some embodiments of the present invention. [Figure 9C3] 1A and 1B are schematic diagrams of exemplary gimbal blocks with extensions coupled thereto, according to some embodiments of the present invention. [Figure 9D] 1A-1C are schematic diagrams of exemplary wire locking elements, according to some embodiments of the present invention. [Figure 9E1] 1A-1C are schematic diagrams of several exemplary interactions between a wiring end effector module and different types of terminal blocks, according to some embodiments of the present invention. [Figure 9E2] 1 is a schematic diagram of an exemplary ferrule, according to some embodiments of the present invention. [Figure 9E3] 1 is a schematic diagram of an exemplary ferrule, according to some embodiments of the present invention. [Figure 9F] 1 is a flowchart of an exemplary wiring method with an exemplary wiring end effector module, according to some embodiments of the present invention. [Figure 9G] 1 is a flowchart of an exemplary wiring method with an exemplary wiring end effector module, according to some embodiments of the present invention. [Figure 9H] 1 is a flowchart of an exemplary wiring method with an exemplary wiring end effector module, according to some embodiments of the present invention. [Figure 10] 1 is a flowchart of an exemplary wiring method with a wiring arm module, according to some embodiments of the present invention. [Figure 11] 1 is a schematic diagram of an exemplary data flow and operation of an automatic wiring system according to some embodiments of the present invention. [Figure 12] 1 is a schematic diagram of automated electrical wiring of a lighting unit, according to some embodiments of the present invention. [Figure 13] 1A-B are schematic diagrams of a wire end effector for automated electrical wiring of a lighting unit, according to some embodiments of the present invention. [Figure 14]10A-10C are schematic diagrams of exemplary forces used for insertion of a wire into a wire terminal, according to some embodiments of the present invention. [Figure 15] FIG. 1 is a schematic diagram of an exemplary horizontal automatic routing system with a dedicated wire preparation module, in accordance with some embodiments of the present invention. [Figure 16] FIG. 1 is a schematic diagram of another exemplary horizontal automatic routing system with a dedicated wire preparation module, in accordance with some embodiments of the present invention. [Figure 17A] FIG. 1 is a schematic diagram of an exemplary horizontal automatic routing system, in accordance with some embodiments of the present invention. [Figure 17B] FIG. 1 is a schematic diagram of an exemplary horizontal automatic routing system, in accordance with some embodiments of the present invention. [Figure 17C] FIG. 1 is a schematic diagram of an exemplary horizontal automatic routing system, in accordance with some embodiments of the present invention. [Figure 17D] FIG. 1 is a schematic diagram of an exemplary horizontal automatic routing system, in accordance with some embodiments of the present invention. [Figure 18] 1A-B are schematic diagrams of a wiring process with two automated mechanical arms and a horizontal wire preparation module according to some embodiments of the present invention. [Figure 19] 10 is a graph illustrating exemplary phases of inserting a wire into an electrical terminal connector as identified by sensors in the gripper, according to some embodiments of the present invention. [Figure 20] 1A-1C are three different examples of forces sensed by a gripper in three different scenarios, according to some embodiments of the present invention. [Figure 21] 10 illustrates several test experiments of the characteristics of an exemplary scenario, according to some embodiments of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0177] The present invention, in some embodiments thereof, relates to automated electrical wiring systems and methods, and more particularly, but not exclusively, to automated electrical wiring systems and methods for electrical cabinets.

[0178] overview An aspect of some embodiments of the present invention relates to designing wiring for electrical cabinets and performing the wiring by automated machines.

[0179] In some embodiments, the automatic wiring operation includes drafting and simulating optimization of the wiring sequence, which may reduce setup time engineering of the electrical cabinet wiring and shorten the actual wiring execution time. In some embodiments, the automatic wiring machine includes multiple sensors for tactile feedback, which may increase wire insertion into valid locations and shorten the validation process. In some embodiments, the automatic wiring system may perform multiple optimization processes using micro- and macro-motion analysis with artificial intelligence (AI) algorithms to shorten setup time. In some embodiments, the automatic wiring system may utilize deep learning and / or vision-based algorithms for component location and identification, which may increase wire insertion into valid locations and shorten the validation process and improve cabinet wiring cycle / execution time. In some embodiments, the automatic wiring system may utilize reinforcement learning for impedance-controlled wire insertion, and optionally a search routine, all of which may improve the accuracy / performance of wire insertion into valid locations.

[0180] In some embodiments, the automated wiring system includes instructions for enabling wire placement within cable channels / tracks to prevent haphazard routing within a cabinet. In some embodiments, the automated wiring system includes instructions for preventing wire twisting during operations to secure the proper routing of the cable along a path. In some embodiments, the automated wiring system manages cable slack when the cable is held in two places (but not necessarily at two ends). In some embodiments, the automated wiring system includes instructions for avoiding obstacles to the cable along its route within a duct or to the actual cable tray / duct. In some embodiments, the automated wiring system includes instructions for harnessing routes (i.e., connecting harnesses with multiple ends) with collision avoidance and slack management by identifying junctions and optionally fixing slack and cable hang locations. In some embodiments, the automated wiring system includes instructions for taking into account the length and / or number of wires previously positioned within cable tracks / channels for the design and / or routing and / or positioning of multiple wires within an electrical cabinet. In some embodiments, routing a cable within a cable track / channel requires at least two cable manipulators (alternatively, robotic arms, etc.), one to fix the position of the cable (e.g., at a corner) and one to continue positioning the cable within the cable track / channel.

[0181] An aspect of some embodiments of the present invention relates to inserting a wire into an electrical connector by a robotic manipulator. In some embodiments, the robotic manipulator comprises a smart holder including multiple sensors. In some embodiments, the holder comprises a finger-like holder. In some embodiments, inserting the wire comprises manipulating the wire and receiving feedback from multiple sensors regarding the status of the wire and optionally the connector of the component. Hereinafter, the term "connector" refers to the location where a wire and / or wire head is connected on a component. Hereinafter, the term "component" refers to any component that is part of an object requiring wiring (e.g., an electrical cabinet) and that includes a connector to which the wire and / or wire head can be connected, such as a circuit breaker, electrical part, computer component, electronic part, etc. The term "wire head" hereafter refers to any end of a wire, regardless of whether it includes a dedicated attachment (e.g., a ferrule) or a dedicated connector for only the bare metal wire (e.g., for data and / or video and / or networking, etc.).

[0182] One aspect of some embodiments of the present invention relates to the manipulation of a wire by two robotic manipulators, where the robotic manipulators hold the wire from two different points on the wire. In some embodiments, manipulating the wire includes maintaining a constant level of tension on the wire. In some embodiments, manipulating the wire includes identifying three-dimensional coordinates for each of the two manipulators relative to a target while holding the wire to perform a wiring action. In some embodiments, before describing at least one embodiment of the present invention in detail, it should 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.

[0183] Referring now to the drawings, FIG. 1A shows a schematic diagram of an exemplary autorouting system according to some embodiments of the present invention.

[0184] 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.

[0185] 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.

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

[0187] 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.

[0188] Design Console Example In some embodiments, the design console 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, where the wire information 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, boards, etc.

[0189] 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 through automatic part selection.

[0190] 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.

[0191] In some embodiments, the database 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.

[0192] 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 routing design, and the actual wiring of the cabinet, including the actions 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.

[0193] 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 identify the cabinet and / or component type. In some embodiments, the system then creates a wiring blueprint based on the scan and BOM.

[0194] 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.

[0195] 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.

[0196] 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 be passed 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, can be automatically created using dedicated extensions.

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

[0198] 1B , a flowchart of an exemplary method for merging electrical schematics with mechanical drawings within and by the design console 102 is shown, according to some embodiments of the present invention. In some embodiments, a user provides and / or inserts rules for the electrical schematics 120 and / or mechanical drawings 122 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 124 and / or mechanical drawings 126 in the design console 102 itself. In some embodiments, different designs are provided by different users and inserted independently into the design console 102. In some embodiments, 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 (128 / 130). 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 corrected design created elsewhere. In some embodiments, once the design is approved, the design console 102 creates the underlying wiring plan by merging (132) between the electrical and mechanical schematics. In some embodiments, after merging, the design console 102 optionally performs additional checks of the rules for each design to ensure that all rules are still maintained (134). In some embodiments, the system then proceeds to prepare a robot wiring plan (136).

[0199] 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.

[0200] 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 .

[0201] 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.

[0202] 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 into a device before 12 to avoid collisions / obstacles), and sequence optimization based on other priorities (e.g., reducing cycle time).

[0203] In some embodiments, the design console utilizes a simplified model of the electrical panel design to check for clashes in the full 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.

[0204] Simulation Module Example 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.

[0205] 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.

[0206] Example of dividing a task into macro-processes and micro-processes In some embodiments, the design console software includes instructions for dividing the overall auto-wiring process into multiple macro-processes, including multiple micro-processes. In some embodiments, an optimization process, including the use of simulation, ensures that the macro- and micro-processes perform in an optimal manner according to their tasks, optionally by optimizing most, if not all, of the macro- and micro-processes. In some embodiments, the auto-wiring 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, optionally correlating 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.

[0207] 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.

[0208] In some embodiments, the micro-operation library is part of a third-party entity that provides the corresponding micro-operations to the tool, 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.

[0209] 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.

[0210] 2 and 3, there are shown a circuit diagram ( FIG. 2 ) and a schematic diagram ( FIG. 3 ) of an exemplary automatic wiring unit / system 106, according to some embodiments of the present invention. In some embodiments, the exemplary automatic wiring unit / system 106 includes one or more modules as part of and / or within a main casing 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 (shown only in FIG. 2 ), and a software module 214 (shown only in FIG. 2 ).

[0211] 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.

[0212] In some embodiments, the software module 214 is also responsible for debugging the system and performing and / or scheduling system maintenance.

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

[0214] 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. may also be edited by the user. In some embodiments, a user can add testing and / or QA routines to the runtime software.

[0215] Panel Handling Module 210 Example In some embodiments, various panel handling modules can support the process of loading and unloading panels into the system 106. In some embodiments, 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 install 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. 15 ).

[0216] 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.

[0217] QA Module 212 Example In some embodiments, the QA module 212 communicates with all modules of the automatic wiring unit / system 106 and is configured to perform actions 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 electrical cabinets, 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.

[0218] 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.

[0219] 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 the two elongated extensions 910a-b (see below) or through specific tools that can be attached (automatically or manually) to the wiring arm module. For example, 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.

[0220] 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.

[0221] 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.

[0222] 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.

[0223] In some embodiments, the automated wiring system may utilize reinforcement learning for impedance controlled flexible wire insertion to increase wire insertion in reasonable locations.

[0224] 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 components before and / or during wire insertion. In some embodiments, the automatic wiring system performs a dry run (scan) on the component to validate the location of the connector openings in the component (using various sensors, such as visual, optical, tactile, etc.) and provide corrective delta positions before performing the insertion routine.

[0225] Wire Preparation Module 204 4, a schematic diagram of an exemplary wire preparation module 204 is shown, according to some embodiments of the present invention. In some embodiments, the automatic wiring unit / system 106 includes the wire preparation module 204. In some embodiments, the wire preparation module 204 is an integral part of the automatic wiring unit / system 106. In some embodiments, the wire preparation module 204 is 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.

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

[0227] 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.

[0228] Frame 412 example In some embodiments, wire preparation module 204 comprises a frame 412 configured to house all modules and components of wire preparation module 204. In FIG. 4, frame 412 is a vertical frame. To facilitate understanding of the present invention, the following description refers to a vertical frame as shown in FIG. 4. It should be understood that other configurations of wire preparation module 204 in general, and frame 412 in particular (see, e.g., the exemplary horizontal automated wiring cabinet below), remain within the scope of the present invention. In some embodiments, a potential advantage of having a vertical frame is that it allows different components of wire preparation module 204 to be positioned in a sequential manner, which also allows for easier movement of the wire by wire manipulator 404 during the wire preparation process. In some embodiments, the length of frame 412 determines the maximum length of rail 410.

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

[0230] In some embodiments, either before or after attaching a wire end connector to the stripped wire, the wire itself can optionally be marked with a wire marking device as disclosed above.

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

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

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

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

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

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

[0237] Example of Wirestock 402 In some embodiments, the wire preparation module 204 includes a plurality of wire stocks 402. In some embodiments, the wire stock includes a plurality of different types of wires used in the electrical cabinet, such as shielded wires, wires of different gauges, wires of different colors, and / or different types of insulation, such as for RF. In some embodiments, the wire stock is optionally coupled to an automatic feeder configured to release as much wire as needed, for example, configured to release the required length of wire. In some embodiments, a labeling module 409 is added to the wire preparation module to mark the wires. In some embodiments, labels can be printed on sleeves and inserted into the wires before the end pieces. In some embodiments, printed labels are attached to the wires (called flags). In some embodiments, the indications are printed directly on the wires.

[0238] Wire preparation method examples 6A-C, a flowchart of an exemplary wire preparation method is shown, according to some embodiments of the present invention. In some embodiments, the system receives information regarding a required wire (602). In some embodiments, the information regarding the wire includes one or more of the wire type and the wire length. In some embodiments, a first wire manipulator grasps the end of a selected wire (604). In some embodiments, the first wire manipulator moves the end of the wire into a stripper module 406, thereby stripping the wire core and exposing the wire core (606). In some embodiments, optionally, the first wire manipulator moves the stripped end of the wire into an associated wire-end connector attachment module 408, thereby attaching a wire-end connector / wire head onto the stripped wire core (608). In some embodiments, optionally, the first wire manipulator moves the end of the wire into a labeling module 409, thereby marking the wire (609) and / or providing identification.

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

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

[0241] In some embodiments, if the answer is "yes" (following the letter "A" in FIG. 6B ), the wire manipulator holding the wire to which the wire end connector has just been attached positions itself from the second wire manipulator at the distance necessary to provide the required length of wire (612). In some embodiments, the second wire manipulator picks up a location selected according to the wire and the required length (614). In some embodiments, the second wire manipulator moves the wire toward the wire cutter 414, which cuts the wire, thereby creating a second end of the wire (616). In some embodiments, while the wire cutter cuts the wire, the second wire manipulator continues to hold the end of the wire that was just cut. In some embodiments, the second manipulator moves the second end of the wire into the stripper module 406, stripping the wire core of its covering and exposing the wire core, just as was performed with the first end of the wire (618). In some embodiments, optionally, a second wire manipulator attaches a wire end connector onto the stripped wire core by moving the stripped second end of the wire into an associated wire end connector / wire head attachment module 408 (620). In some embodiments, optionally, the second wire manipulator marks the wire (621) and / or provides a second identification by moving the end of the wire into a labeling module 409. In some embodiments, at this point there is a wire with two ends with the required connectors held by two different wire manipulators. In some embodiments, at this point the wire ends are delivered to a wiring arm module (622) (described in further detail below) for further insertion into a wire cabinet.

[0242] Returning to FIG. 6A , if the answer is “no” (following the letter “B” in FIG. 6C ), the wire manipulator holding the wire that just had the wire end connector attached delivers the first end to the wiring arm module (624) and uses both arms of the wiring arm module to pull the wire to the required length (608). In some embodiments, when this length reaches either the first or second wire manipulator, either picks up the wire and a location selected according to the required length (630). In some embodiments, the first / second wire manipulator moves the wire toward the wire cutter 414, which cuts the wire, thereby creating a second end for the wire (632). In some embodiments, the first / second wire manipulator continues to hold the end of the wire that was just cut while the wire cutter cuts the wire. In some embodiments, in the same manner as was performed on the first end of the wire, the first / second manipulator moves the second end of the wire into the stripper module 406 to strip the coating from the wire core and expose the wire core (634). In some embodiments, optionally, the first / second wire manipulator moves the stripped second end of the wire into the associated wire-end connector attachment module 408 to attach a wire-end connector onto the stripped wire core (636). In some embodiments, optionally, the first / second wire manipulator moves the end of the wire into the labeling module 409 to mark the wire (637) and / or provide identification. In some embodiments, at this point, there is a wire with two ends equipped with the required connectors, one end held by the wiring arm module and the second end held by the first / second wire manipulator. In some embodiments, at this point, the second wire end is delivered to the wiring arm module for further insertion into a wire cabinet (discussed in further detail below).

[0243] Example of a wire feeding unit In some embodiments, wires are provided that are ready to be used by providing pre-cut wires that are 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 the mechanical arm module. In some embodiments, when pre-cut wires are used and made available to the 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, for example, fixtures 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, for example, using a manipulator, dual arms, pneumatic shaft, etc.

[0244] 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 that 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 for the user to "feel" that the wire is fixed in place by pulling the wire slightly after the locking action has been performed. 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.

[0245] 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:

[0246] 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. 7A , 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 702, 704, and 706. In some embodiments, the joints provide multiple degrees of freedom of movement. For example, joints 702, 704, and 706 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.

[0247] 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.

[0248] In some embodiments, portions of the arms and / or grippers may be automatically adapted for dedicated tasks, such as holding different tools, such as tweezers or cutters.

[0249] Grasp and slide function: When performing a wire action, humans use tactile feedback to secure the cable to the connector / device, and a typical action cycle includes the following (see Figures 7B1-7B5): · The contact force is zero and before increasing during insertion, a radial force is applied to the wire (radial force, Fig. 7B1) and an insertion force (axial force, Fig. 7B2) is applied to grasp the wire; At a certain peak force (determined by the user's experience), the human "feels" the wire is plugged into the component connector (peak force, Figure 7B3). Typically, at this point, the axial force is counteracted by fully plugging 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 7B4); Next, the user reduces the radial force (grip) on the cable, allowing it to slide axially in their hand (Figure 7B5). Typically, the user will feel the cable sliding without having to release the wire.

[0250] In some embodiments, these actions are performed using what are referred to herein as squeeze and slide functionality.

[0251] In some embodiments, the wire arm module 206 with the wire end effector module 208 includes multiple motors and sensors to perform force and axial and radial force measurements similar to actions performed by a human to provide a system with a high level of dexterity and perception capable of performing wire actions. In some embodiments, the wire end effector module 300 includes one or more optical sensors, such as one or more cameras and / or laser scanners. In some embodiments, the wire end effector module 300 includes multiple 2D and / or 3D cameras.

[0252] Example of wiring arm module 206 8A-B, 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 802 mounted on a rail 804. In this example, the rail 804 comprises two vertical tubes on which the entire wiring arm module moves vertically, as indicated generally by arrow 806. In some embodiments, a mechanical arm 808 mounted on the base 802 comprises multiple arm sections 810, 812 and joints 702, 704, 706. In some embodiments, the end of the mechanical arm 808 is a wiring end effector module 208. Referring now to FIG. 8B, 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 to provide 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 comprises a wire end effector module 208, which optionally includes a camera 850. It should be understood that in any of the embodiments of the wire end effector module 208, a camera is optionally added.

[0253] 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.

[0254] In some embodiments, a typical arm has a payload of approximately 10 kg and an accuracy of better than 0.1 mm. In some embodiments, 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.

[0255] Example of a Wire End Effector Module 208 9A, a schematic diagram of an exemplary wired end effector module 208 is shown, according to some embodiments of the present invention. In some embodiments, the wired end effector module 208 comprises one or more of the following components: a wire retaining element 902 and a wire locking element 904. Referring now to FIG. 9B, a schematic diagram of the components of the wire retaining element 902 is shown, according to some embodiments of the present invention. In some embodiments, the wire retaining element 902 comprises one or more of a base 906 that includes a wire clamping element 908. In some embodiments, the wire clamping element 908 comprises two extensions 910a-b, optionally two elongated finger-like extensions, that are connected, for example, by an electrical mechanism 912 and / or a pneumatic mechanism. In some embodiments, the wire clamping element 908 comprises a gimbal block 970 that connects the two extensions 910a-b (see further description below regarding the gimbal block 970). In some embodiments, the base 906 includes a motor 914 that enables horizontal movement of the wire holding element 902 in the direction indicated generally by arrow 916. In some embodiments, alternatively or additionally, a wiring arm module provides movement along the schematic arrow 916. In some embodiments, the horizontal movement indicated by arrow 916 is in a direction along the axis of the wire toward the electrical terminal connector. 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.

[0256] Referring now to FIG. 9C1 , a schematic diagram of sensors located on elongate extensions 910 a-b is shown, according to some embodiments of the present invention. In some embodiments, one or more of the elongate extensions 910 a-b include one or more sensors 918 configured to monitor the force applied by the elongate extensions 910 a-b to a wire 920. 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 measurements, as described above, providing the system with a high level of dexterity and perceptual capabilities to perform wire actions 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 970 in FIG. 9C2 ), as shown and described in FIGS. 9C2-9C3 below.

[0257] In some embodiments, the wire holding element 902 functions to hold the wire upon receiving it from the wire manipulator 404 of the wire preparation module 204 .

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

[0259] In some embodiments, the electrical mechanism 912 includes an anti-collision mechanism to protect the fingers.

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

[0261] 9C2-9C3, 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, the gimbal block 970 comprises multiple components that allow for monitoring of forces applied to the extensions 910a-b. 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. 9C2, the gimbal block 970 comprises a top block 972 that couples the gimbal block 970 to the rest of the device. In some embodiments, a top connector 974 is located below the top block 972 and is coupled to the top block 972 by a screw 976 or the like. In some embodiments, one or more damping springs 996 in communication with one or more button axis load cells 978 are housed between the top block 972 and the top connector 974. In some embodiments, calibration of the load cell is performed by actuating a damping force calibration set screw 980. In some embodiments, below the top connector 974 is a central block 982. In some embodiments, there is a first gimbal axis 984 inserted into the top side of the central block 982, providing a horizontal axis of motion perpendicular to the pin of the first gimbal axis 984 (see below for gimbal block motion). In some embodiments, there is a second gimbal axis 986 inserted into the bottom side of the central block 982 (shown in inserted position). In some embodiments, the second gimbal axis 986 is perpendicular to the first gimbal axis 984. In some embodiments, the second gimbal axis 986 provides a horizontal axis of motion perpendicular to the pin of the second gimbal axis 986 (see below for gimbal block motion). In some embodiments, below the central block 982 is a bottom connector 988, connected at the top to the central block 982 and at the bottom to a bottom block 990.9C2, 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 the bottom connector 988 and the bottom block 990. In some embodiments, the extensions 910a-b are coupled to the bottom block 990.

[0262] In some embodiments, the device includes one gimbal block 970 connecting both extensions 910a-b, or in some embodiments, the device includes two gimbal blocks 970, one for each extension, as shown, for example, in FIG.

[0263] Referring now to FIG. 9C3 , 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 970 comprises a first gimbal axis 984 that provides movement of the gimbal block 970 in a first axis and a second gimbal axis 986 that provides movement of the gimbal block 970 in a second axis. FIG. 9C3 shows a side view of the gimbal block 970, illustrating the movement (arrow 992) enabled by the first gimbal axis 984. FIG. 9C3 also shows a front view of the gimbal block 970, illustrating the movement (arrow 994) enabled by the second gimbal axis 986. In some embodiments, the first gimbal axis 984 and the second gimbal axis 986 provide the gimbal block 970 with two distinct axes of rotation. In some embodiments, these axes of rotation are used in conjunction with single-axis load cells to measure moments and forces applied to the extensions. In some embodiments, as shown in Figure 9C3, the two extensions are each separately coupled to a gimbal block 970, allowing for measurement of different forces on each extension. In some embodiments, when the gimbal mechanism reaches a limit of rotation (motion), which optionally implies access to the force applied to the extension (e.g., during a possible collision of the device with an electrical panel), the system may stop the wire insertion operation and / or take corrective action (e.g., move the device).

[0264] 9D , a schematic diagram of an exemplary wire locking element 904 is shown, according to some embodiments of the present invention. In some embodiments, the wire locking element 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 904 is not required and is therefore not used. In some embodiments, a screw terminal or screw-type terminal block secures the wire to the conductor in the terminal block by tightening a screw to close the clamp. In some embodiments, a push-button terminal block secures the wire to the conductor with a spring clamp that opens by pressing a button. In some embodiments, releasing the button clamps the spring onto the wire. In some embodiments, similar to a push button with a spring clamp, a push-in terminal block allows the wire to be directly pressed into the housing without using a push button to release the spring. In some embodiments, depending on the type of locking mechanism in the terminal block (component), the wire locking element 904 includes a dedicated actuator 922. For example, in FIG. 9D , the wire locking element 904 includes a flathead screwdriver 922 used to secure a screw terminal block. In some embodiments, the head of the actuator and / or drill bit 322 can be replaced manually, or optionally automatically (e.g., by moving the device to an exchange rack, which uses vertical movement 330 to exchange the head of the actuator 322). Referring now to FIG. 9E1 , 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.

[0265] Returning to FIG. 9D , in some embodiments, the wire locking element 904 includes a motor 924 configured to actuate a dedicated actuator 922. In some embodiments, the motor 924 and dedicated actuator 922 are carried by a base 926, which is further coupled to a second motor 928 that performs the vertical movement, as indicated generally by arrow 930, required to insert the dedicated actuator 922 into the terminal block. In some embodiments, although not shown in FIG. 9D , multiple motors are used to provide multiple directions of movement for the wire locking element 904. In some embodiments, the wire locking element 904 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 904 is that it enables the device to interact with multiple electrical terminal connectors, each with a different position for accessing the wire locking mechanism.

[0266] In some embodiments, the wire locking element 904 comprises a torque sensor configured to monitor a torque force applied by an 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.

[0267] Example of using a wire with an end terminal (wire head) ferrule 9E2-9E3, 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 9002, optionally having a metallic distal end 9004, that is 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 rigid. 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 ferrule can have different dimensions, for example, as shown in FIG. 9E2. In some embodiments, the ferrule can have a differently shaped metal part 9004 at its distal end, for example, as shown in FIG. 9E3. In some embodiments, the ferrule includes a cap 9002 that is stiffer than the wire itself, so the wiring end effector module 208 clamps the cap 9002 instead of clamping the wire directly. In some embodiments, a potential advantage of clamping the cap 9002 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 cause deflection of the head of the wire that needs to be inserted into the electrical terminal connector. Clamping the cap 9002 can potentially prevent this. In some embodiments, the ferrule is configured to be fully inserted into the component's electrical terminal connector, meaning that the cap 9002 needs to be fully inserted inside the component's electrical terminal connector to ensure a proper connection. In some embodiments, the method of inserting a wire into a component's electrical terminal connector during use of a wire with a ferrule includes additional steps, as further disclosed below.In some embodiments, additional actions that must be performed during insertion of a wire including a 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 back, re-clamping the wire at a position distal to the ferrule, and finishing inserting the wire and ferrule into the electrical terminal connector of the component. In some embodiments, before 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. 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 the locking mechanism of the electrical terminal connector, allowing the wire to be further inserted into the electrical terminal connector. In some embodiments, the wiring end effector module 300 comprises an additional element configured to hold the wire in place while the extension is moved to a more distal position on the wire. In some embodiments, the additional element can be a third extension configured to extend as needed and hold the wire in place.

[0268] In some embodiments, the extension / end effector is capable of inserting complex shaped ferrules, such as forked or ring ferrules, into the connector.

[0269] 9F , a flowchart of an exemplary wiring method by an exemplary wiring end effector module 208 is shown, according to some embodiments of the present invention. In some embodiments, the elongate extension grasps the wire (950) by applying a radial force to the wire. In some embodiments, the force applied to the wire is about 5 N to about 15 N, optionally about 7 N to about 20 N, optionally about 8 N to 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 1 N. In some embodiments, the effector module approaches the wire to the connector (952) by applying an axial force. In some embodiments, the force applied to the wire is about 5 N to about 15 N, optionally about 7 N to about 20 N, optionally about 8 N to 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 1 N. In some embodiments, the wire is then inserted into a hole in the component's connector (954). In some embodiments, the system senses resistance on the wire due to the fact that the wire has reached the end of the hole in the connector (956). In some embodiments, the system then secures the wire in the component's connector (958) (see the above method of securing a wire in a connector). In some embodiments, the system then pulls back the wire by gently applying an axial force in the opposite direction while sensing resistance from a gabbing sensor to assess a solid connection of the wire in the connector (960). In some embodiments, the system slightly reduces the radial force on the wire while continuing to hold it (962). In some embodiments, if the insertion of the wire was the last wire 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 while moving the mechanical arm away from the connector (964). In some embodiments, the system continues with the wiring process (966) as described elsewhere.

[0270] 9G , a flowchart of an exemplary wiring method by 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 extension grips the wire by applying a radial force to the ferrule (9006). In some embodiments, the force applied to the ferrule is about 3 N to about 110 N, optionally about 7 N to about 20 N, optionally about 8 N to 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. In some embodiments, the effector module approximates the ferrule to the connector by applying an axial force (9008). In some embodiments, the force applied to the wire is about 3 N to about 15 N, optionally about 7 N to about 20 N, optionally about 8 N to 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 0.25 N. In some embodiments, the ferrule is then partially inserted into the hole of the component connector (9010). In some embodiments, the system optionally partially closes a locking mechanism in the electrical terminal connector to hold the ferrule in place (9012). In some embodiments, the wire with the ferrule is held in place (9014). In some embodiments, this is performed by one or more additional elements disclosed above. In some embodiments, the extension is actuated to release the ferrule (9016). In some embodiments, the device then moves back along the wire (9018). In some embodiments, the extension re-grabs the wire itself (9020). In some embodiments, optionally, the system opens a previously partially closed locking mechanism of the electrical terminal connector (9022). In some embodiments, the system then applies an axial force to the ferrule, which has been fully inserted into the electrical terminal connector (9024). The flowchart continues in FIG. 9H after the letter A. In some embodiments, the system senses resistance on the wire by the fact that the wire has reached the end of a hole in the connector (9026).In some embodiments, the system then secures the wire within the connector of the component (9028) (see the method above 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 gab sensor to assess a solid connection of the wire within the connector (9030). In some embodiments, the system slightly reduces the radial force on the wire while continuing to hold it (9032). In some embodiments, if the wire insertion was the last wire connected to the component in the electrical panel, the method ends. In some embodiments, the system moves the mechanical arm away from the connector while allowing the wire (still held by the elongated extension) to slide into the elongated extension without releasing the wire (9034). In some embodiments, the system continues the wiring process as described elsewhere (9036).

[0271] In some embodiments, parameters sensed by one or more sensors, 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.

[0272] Example of wire management held by two wiring arm modules In some embodiments, when a wire is held by two wiring arm modules, the system includes instructions to hold the wire in a specific manner. For example, the wire is held in a specific position relative to the electrical cabinet. In another example, the wire is held with a certain tension between two points on the wire held by the two arms. In some embodiments, a set of instructions is prepared and provided to each arm module during the wiring blueprint creation process. In some embodiments, this is done to allow the robotic arms to function without potentially causing damage to each other, the electrical cabinet, the wire, and / or tangling the wire 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 while the other mechanical arm holds the other end toward its assigned location in the electrical cabinet (optionally above the duct / DIN) while maintaining tension.

[0273] In some embodiments, the functions of holding and tensioning the wires are interchangeable between the two mechanical arms. For example, at the beginning of a wiring action, a first mechanical arm holds the wire and prevents it from moving, while a second mechanical arm slides and moves 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 and moves the wire toward the location in the electrical cabinet where it will be positioned.

[0274] 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, for example, 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. 7B1-7B5 and 9F).

[0275] 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 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.

[0276] 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.

[0277] In some embodiments, a vision system is used to validate the process before the wire is placed into the duct.

[0278] In some embodiments, the movement of two wiring arms for wiring cabinets, 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 plan of the wires in the panel, requires a high level of synchronization and precision during the movement of the arms at multiple levels.

[0279] 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 be the support arm during the wiring process, and vice versa. In some embodiments, the support arm keeps the wire under 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. In some embodiments, the support arm keeps a portion of the wire, e.g., the portion of the wire held between the two wiring arms, under tension and leaves other portions untensioned (the wire slacks and / or hangs behind the wire end effector) during the wiring process. In some embodiments, the slack length is about 10% to about 30% of the total length of the wire being routed. Optionally, it is about 5% to about 40% of the total length of the wire being routed. Optionally, about 1% to about 50% of the total length of the wire being routed. For example, 15%, 20%, or 25% of the total length of the wire being routed. In some embodiments, during the routing process, the slack wire is kept above the plane on which the panel components are located (if the routing is performed from above on horizontally oriented panels, see e.g., FIG. 15) and / or is spaced from the plane on which the panel 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. In some embodiments, as the leading arm moves towards the insertion point and guides the wire along the planned 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 a 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.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 may be 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. 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 without pulling and / or distorting the wire while changing direction at the required point in the path.

[0280] 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, for example by a first arm, the second arm becomes a leading arm and guides the wire toward the second component, and the first arm becomes a supporting arm.

[0281] In some embodiments, the support arm performs one or more of the following actions: secures 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; validates the routing process using one or more sensors (e.g., cameras, force sensors, laser line sensors, and / or proximity sensors). In some embodiments, a safety zone is defined, e.g., above the component level (if the wiring is run from above on a horizontally oriented panel, see e.g., FIG. 15) and / or is spaced from the plane on which the panel's components are located (if the wiring is run from the side on a vertically oriented panel, 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. 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 support arms slide along the wire, positioning it in place along its path on the panel, while the leading arms guide the distal end of the wire to its next point within the panel.

[0282] 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.

[0283] Examples of optimization features in 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.

[0284] Cartridge for wasted wire during the wiring process In some embodiments, as described above, the support wiring arm supports the actions performed by the leading wiring arm while the leading wiring arm positions the wire along the path depicted in the blueprint within the cabinet. In some embodiments, one of these support actions is holding the remaining portion of the wire that the leading wiring arm is “trailing” while moving the end of the wire through the wiring path. In some embodiments, the wiring arms optionally include a dedicated cartridge in which waste wire is wound and / or held when a particular wire arm functions as a support wiring arm. In some embodiments, because the roles of leading and support can change during the wiring process, both arms optionally include dedicated cartridges. 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 waste 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 wires remain housed during the wiring process, potentially avoiding waste wire from causing damage or becoming tangled during the wiring process.

[0285] Example of removing obstacles using a support wiring arm In some embodiments, if and when during the routing process, the wire positioned in the cabinet by the leading routing 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 routing arm and perform actions to resolve these issues. For example, the support routing arm may move obstacles (e.g., other wires already positioned in the cabinet) away from the positioned wire, optionally using a specialized tool (e.g., tweezers, a thin rod) that allows it to interact with the other wires without damaging them. In some embodiments, optionally, the support routing arm does not hold the positioned wire while removing the obstacle. 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.

[0286] Use of 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 overall wiring process of the cabinet. In some embodiments, optionally, for short wires, the wiring arm secures 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 position. 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.

[0287] Use of grip and slide 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).

[0288] 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 into the panel. In some embodiments, actuation is performed using an extension. In some embodiments, actuation is performed using a dedicated actuation device. In some embodiments, switching a 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.

[0289] Complex Wire Usage In some embodiments, the system is configured to handle 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.

[0290] Example of using the system for wiring harnesses inside a cabinet 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 within a cabinet. In some embodiments, the system includes information about sensory feedback, e.g., force, torque, and visual feedback, recorded when connecting these types of wire heads. In some embodiments, the sensory feedback is used to validate that the wire head is properly plugged into place. In some embodiments, after the wire head is plugged into place, a locking actuator is used to secure the wire head in place, for example, by tightening a screw on a connector within the component. In some embodiments, a dual push action (i.e., push, release, and re-grasp) is used to plug the wire head.

[0291] Optional division of tasks in the timeline In some embodiments, the system is configured to perform part of a task, stop, perform another task, and then select and finish the previous task. For example, connect one end of a wire to one connector, position the wire along a path drawn on a blueprint, release the wire, perform another task, 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.

[0292] Example of a wire end effector with multiple degrees of freedom 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.

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

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

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

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

[0297] In some embodiments, the DIN rail has markings at one or both ends to allow for precise location and identification of the location within the rail relative to the panel. Optionally, in some embodiments, marking components are added to the end of each array of components mounted on the DIN rail to identify the end and / or start locations of the components placed on the DIN rail.

[0298] In some embodiments, the wires are positioned in a panel without a duct, and after some or all of the wire positioning is completed, an inverted duct (meaning it has an opening at the bottom and is covered at the top) is positioned on top of the wires to close the wires in a closed duct.

[0299] Smart Wire Example In some embodiments, the electrical panel is wired with smart wires configured to assist in the automated wiring process. For example, the wires can include one or more clips and / or holders and / or attachable reversible connectors for the wires, which hold the wires in place once inserted into the duct / DIN. In some embodiments, a potential advantage of this is that it allows already placed wires not to interfere with the remainder of the wiring process. In some embodiments, the wires include one or more position markers, which are also stored in the design console 102 and used by the mechanical arm for identification during the wiring process. In some embodiments, the wires may include a connecting material (e.g., adhesive), which keeps the wires in place once they are positioned, and optionally, the adhesive on the wires can cure after placement. In some embodiments, the wires include a roughened surface to assist the elongated member in gripping the wires. In some embodiments, the wires have a different cross-section, e.g., a square cross-section, to support better placement of the wires within the duct.

[0300] Example of a ductless electrical cabinet In some embodiments, the electrical cabinet may not include ducts at all, for example by providing smart wires that can be attached to each other, and these wires are what hold the wires in place.

[0301] Example of wiring method using wiring arm module 206 10 , 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 (1002). In some embodiments, the wire preparation module prepares the wire as disclosed herein (1004). In some embodiments, a first end of the wire is picked up by the wiring arm module (1006). In some embodiments, the first end of the wire is maneuvered into position within an electrical cabinet (1008). In some embodiments, the wiring arm module 206 performs validation (1010) by inserting the first end of the wire into a terminal connector of a first component, locking the wire into the terminal block, and “feeling” the slippage of the elongated extensions 910 a-b, for example, by pulling back slightly on the wire rather than increasing force. In some embodiments, a second end of the wire is picked up by the wiring arm module (1012). In some embodiments, the second end of the wire is maneuvered into position within the electrical cabinet (1014). In some embodiments, manipulating the second end of the wire includes routing the wire from the position where the first end of the wire was inserted through the wire channel / track until the second end of the wire reaches that position. In some embodiments, the two wire arm modules work in concert to insert the 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. It should be understood that the above examples are merely illustrative and in no way limiting of the present invention.

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

[0303] Data Flow and Operation Examples 11 , 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 (1102). In some embodiments, the user runs a simulation in specialized software (1104). In some embodiments, the blueprint is optionally optimized taking into account the results of the simulation (1106). 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 (1108). 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 blueprint 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 (1110).

[0304] In some embodiments, at this point, the system generates 1111 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 and evaluating problems that may occur during the actual wiring of the electrical cabinet, as described elsewhere herein. In some embodiments, optionally, the system runs a simulation to optimize the wire routing sequence, optionally according to the determined parameters.

[0305] In some embodiments, the above actions include continuous data exchange between the server and the computer of the user designing the electrical circuit (1112). 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 (1114). In some embodiments, during assembly, the automated electrical distribution unit / system 106 communicates with the server for continuous monitoring of performance (1116).

[0306] Examples of lighting wiring devices In some embodiments, the automated electrical wiring system is used to wire lighting units. The following paragraphs disclose examples of uses for the automated wiring system. It should be understood that the following are merely examples of uses for the automated wiring system provided to enable those skilled in the art to understand the present invention and are in no way limiting. Referring now to FIG. 12 , a schematic diagram of the automated electrical wiring of a lighting unit 1200 is shown, according to some embodiments of the present invention. In some embodiments, the automated electrical wiring for the lighting unit 1200 comprises a base 1202 to which different components of the automated electrical wiring for the lighting unit 1200 are attached. In some embodiments, the automated electrical wiring for the lighting unit 1200 comprises at least one robotic arm 1204 including a wire end effector 1206. In some embodiments, the automated electrical wiring for the lighting unit 1200 optionally comprises additional robotic arms configured to assist the main robotic arm 1208. In some embodiments, the automated electrical wiring for the lighting unit 1200 optionally comprises a depth camera 1210 configured to monitor the wiring actions of the system. Also shown in FIG. 12 is an exemplary lighting panel 1212 in position where the wiring process will be performed.

[0307] 13A-B, schematic diagrams of an exemplary wire end effector 1206 for automated electrical wiring of a lighting unit 1200 are shown, according to some embodiments of the present invention. In some embodiments, the automated electrical wiring system is used, for example, in a lighting unit / apparatus (see below). In some embodiments, the wire end effector 1206 comprises a mechanical wire feeder 1302 including a dedicated motor 1304 configured to feed the required wire 1306 to a gripper 1308. In some embodiments, as described above, the gripper 1308 comprises two (optionally finger-like) extensions 1310a-b configured to pinch and hold the wire 1306. In some embodiments, each extension is coupled to a force applying mechanism 1312a-b, which is configured to effect movement of the two extensions 1310a-b to actuate the pinching / holding action. In some embodiments, a dedicated motor 1314 is coupled to the force applying mechanisms 1312a-b. In some embodiments, the wire end effector 1206 optionally includes an end wire cutter 1316 configured to remove insulation around the wire and expose the core of the wire. In some embodiments, the wire end effector 1206 optionally includes a vacuum system (not shown) configured to pick up waste from the end wire cutter 1316 and transport it into a waste container 1318.

[0308] Referring now to FIG. 14 , a close-up schematic view of a gripper 1308 and extensions 1310 a-b is shown, according to some embodiments of the present invention. Same part numbers are used. In some embodiments, the gripper 1308 includes one or more sensors 1320 on the extensions 1310 a-b configured to monitor the force applied by the gripper 1308. In some embodiments, the sensors are alternatively or additionally located in the gimbal block(s) 370 holding the extensions, as described above. In some embodiments, as shown schematically in FIG. 14 , the gripper 1308 applies and monitors forces in three main directions (marked as Fin1, Fin2, and Fin3). In some embodiments, these forces are used to insert the wire 1306 into the wire terminal 1322, as shown schematically on the left side of FIG. 14 . In some embodiments, these forces (Fin1, Fin2, and Fin3) are from about 5 N to about 15 N, optionally from about 7 N to about 20 N, optionally from about 8 N to 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.

[0309] Example of a horizontal automatic routing system with a dedicated wire preparation module In some embodiments, the automated wiring system is configured to be mounted on a horizontal platform. In the automated wiring systems shown in Figures 1A-B, 3, and 4, the automated wiring system is mounted on a vertical platform that allows for the connection of wires on upright cabinets, with a wire preparation module nearby to provide the necessary wires, as disclosed herein. In the automated wiring system shown in Figure 12, the automated wiring system is mounted on a horizontal platform that allows for the connection of wires on objects that are located on the platform, with a wire feeder integrated into the wire end effector 1206.

[0310] In the following paragraphs, a variant of the horizontal automatic routing system with a dedicated wire preparation module is disclosed.

[0311] Referring now to FIG. 15 , a schematic diagram of an exemplary automated horizontal wiring system with a dedicated wire preparation module is shown, according to some embodiments of the present invention. In some embodiments, the system is mounted on a horizontal platform 1502, with all necessary equipment located on top of it. As mentioned above, in some embodiments, the system includes one or more wiring arm modules 1504 (two are shown in FIG. 15 ), optionally both including a wiring end effector module 1506 and a wire preparation module 1508 similar to those disclosed above, configured to prepare connection-ready wire 1510 for use (for example) in wiring a panel 1512. In some embodiments, similar to the system disclosed in FIG. 12 , the system optionally includes a depth camera 1514 configured to monitor the wiring action of the system. In some embodiments, the wiring method is the same as that disclosed elsewhere herein.

[0312] Referring now to FIG. 16 , a schematic diagram of another exemplary horizontal automated wiring system with a dedicated wire preparation module is shown, according to some embodiments of the present invention. In some embodiments, the system comprises two separate systems, one allocated near the other. In some embodiments, one system is a wire preparation system 1602, comprising two fully automated mechanical arms 1604 configured to prepare wires 1606 to be inserted into devices 1608. In some embodiments, the other system is an automated wiring system comprising another two automated mechanical arms 1610. In some embodiments, the wire preparation system 1602 can pre-prepare multiple wires 1612 to be left near the automated wiring system 1610. In some embodiments, as with other systems, this system optionally comprises a depth camera 1614 configured to monitor the system's wiring actions. In some embodiments, the wiring method is the same as that disclosed elsewhere herein.

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

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

[0315] Optional installation examples of electrical elements in electrical cabinets In some embodiments, in addition to the automated wiring system, the system of the present invention can be configured to install electrical components in the electrical cabinet prior to the automated wiring process. In some embodiments, a potential advantage of doing this is that all preparation of the electrical cabinet is performed and monitored in the same location.

[0316] Single-arm system example In some embodiments, the system includes a single mechanical arm configured to perform all automated actions of the wiring process. For example, a pre-cut wire ready for wiring is held by the mechanical arm on one side and reeled back onto 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.

[0317] 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.

[0318] 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.

[0319] 18A-B, there is shown a schematic diagram of a wiring process with two automated mechanical arms, according to some embodiments of the present invention.

[0320] FIG. 18A shows a schematic diagram of two automated mechanical arms 1802 / 1804. In the following description, one automated mechanical arm will be referred to as Arm 1 1802 and the other automated mechanical arm will be referred to as Arm 2 1804. Also shown in FIG. 18A is a schematic diagram of an electrical panel 1806 that requires wiring. FIG. 18B shows the schematic diagram of the electrical panel 1806 in more detail. The exemplary electrical panel 1806 includes five ducts 1808-1 / 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.

[0321] Also marked in Figure 18B are circled reference points 1 through 8 for the following discussion.

[0322] 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 before entering duct 1808-3. The wire then needs to bend within duct 1808-3 to reference point 4 and extend into duct 1808-5. The wire then needs to bend within duct 1808-5 to reference point 5. The wire then needs to bend within duct 1808-4 to reference point 6. The wire then exits duct 1808-4 at reference point 7, and continues to reference point 8 before being inserted into component B.

[0323] The following table summarizes the actions of Arm 1 1802 and Arm 2 1804 when placing a wire from Reference Point 1 to Reference Point 8. [Table 1]

[0324] 19, 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. 19 shows the force sensed by sensors on fingers 910a-b of gripper 1308 on a held wire. In some embodiments, the phases are as follows:

[0325] 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 optionally be 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.

[0326] 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.

[0327] 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 attempt, as described above.

[0328] In some embodiments, different types of electrical terminal connectors and different types of wires 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 wires are stored, and according to input provided by a user, the system actuates the gripper accordingly.

[0329] 20A-C, 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 20A 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 sensed force does not increase because the wire does not resist the gripper's pull.

[0330] 20B 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.

[0331] FIG. 20C 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.

[0332] Referring now to FIG. 21 , several test experiments characterizing exemplary scenarios according to some embodiments of the present invention are shown. As previously disclosed, initially, the input from the force sensor remains steady as the gripper moves without resistance from the wire. Next, as the wire enters the component's electrical terminal connector, a spike in the input from the sensor occurs due to resistance between the wire and the connector. Next, the device begins to pull the wire backward 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. 21 . Next, depending on the outcome of the connection between the wire and the electrical terminal connector, various inputs are received from the sensor. In Test 1, the wire came off the connector, as can be seen from the unchanged graph. In Test 2, the wire broke from 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 broke from 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.

[0333] When used herein in reference to an amount or value, the term "about" means "within ±20% thereof."

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

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

[0336] The term "consisting essentially of" means that a composition, method, or structure may include additional ingredients, steps, and / or components, provided that the additional ingredients, steps, and / or components do not materially alter the basic and novel characteristics of the claimed composition, method, or structure.

[0337] As used herein, the singular forms "a," "an," and "the" include plural referents unless the context clearly indicates otherwise. For example, the term "a compound" or "at least one compound" can include multiple compounds, including mixtures thereof.

[0338] 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.

[0339] 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 phrases "range / ranging / ranges between" a first and second designated number, and "range / ranging from" a first designated number "to," "up to," "until," or "through" a second designated number, are used interchangeably herein and are meant to include the first and second designated numbers and all fractional and integer numbers therebetween.

[0340] Unless otherwise indicated, the numerical values ​​used herein and any numerical ranges based thereon are approximations within reasonable measurement precision and rounding errors that one of ordinary skill in the art would understand.

[0341] It is understood that certain features of the invention that are, for clarity, described in the context of separate embodiments, can also be provided in combination in a single embodiment. Conversely, various features of the invention that are, for brevity, described in the context of a single embodiment, can also be provided separately or in any suitable subcombination, or as preferred 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, except to the extent that the embodiment cannot function without those elements.

[0342] 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.

[0343] 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. An automatic electrical wiring system for an object requiring electrical wiring, comprising: a. at least one wiring arm module having a wiring end effector at its distal end for holding and manipulating a wire; b. at least one sensor located within said wire end effector and configured to sense at least one property related to holding and manipulating said wire; c. A circuit comprising: i. receiving a command to perform an electrical wiring activity by using the at least one wiring arm module comprising the wiring end effector; ii. adjusting the manipulation of the at least one wiring arm module and the wiring end effector in consideration of at least one property sensed regarding the holding and manipulation of the wire by the at least one sensor disposed on the wiring end effector caused by the activity; the wire end effector is configured to hold an end of a wire; The circuit further comprises: iii. Inserting the end of the wire into a connector of the object requiring electrical wiring; iv. determining proper insertion and locking of the wire end into the connector by detecting and evaluating resistance to withdrawal of the wire from the connector with the at least one sensor; the circuitry sensing at least one property related to wire retention and manipulation measures axial and radial forces; Automated electrical wiring systems, including:

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

3. The automated electrical wiring system of claim 1 , wherein the wiring end effector includes a wire holding element.

4. The wire holding element comprises a wire clamping element including two extensions, the two extensions having: a. Two elongated extensions; b. Connected by an electrical mechanism; and c. Connected by a pneumatic mechanism; one or more of 4. The automated electrical wiring system according to claim 3.

5. The automated electrical wiring system of claim 1 , wherein sensing the at least one property related to holding and manipulating the wire includes monitoring forces in three primary directions (F in1 , F in2 , F in3 ) relative to the wiring end effector.

6. The wire retaining element a. a motor for movement along a receptacle axis of said connector within said object; b. one or more sensors for monitoring the force applied by the wire clamping element; 5. The automated electrical wiring system of claim 4, comprising one or more of:

7. The wiring end effector includes: one or more sensors for monitoring the force applied to the wire retention element; b. A wire locking element, the wire locking element comprising: i. one or more motors for moving the wire locking element in one or more directions to interact with a locking mechanism within the connector; ii. one or more sensors for monitoring actuation of the locking mechanism of the wire locking element on the locking mechanism in the connector, the wire locking element configured to actuate the locking mechanism in the connector according to predetermined measured parameters monitored by the one or more sensors; a wire locking element comprising one or more of:

5. The automated electrical wiring system of claim 4, comprising one or more of:

8. the circuitry receives the commands to perform the activities on the electrical wiring from at least one design console; a. the at least one design console is one or more of an electronic device, a computer, a tablet, a mobile phone, and a server; b. said at least one design console includes specialized software for the creation of electrical circuit design drawings; c. said at least one design console communicating with at least one server; d. said at least one design console includes specialized software for the creation of mechanical drawings; e. said at least one design console includes dedicated software for the generation of merged electrical and mechanical drawings; f. the at least one design console includes dedicated software for generating a wire routing sequence according to one or more of an electrical schematic and a mechanical drawing; 2. The automatic electrical wiring system of claim 1, wherein at least one of the following is true:

9. The automated electrical wiring system of claim 1 further comprising a monitoring system.

10. The monitoring system includes: a. one or more cameras; b. one or more sensors; c. one or more torque sensors; d. one or more current sensors; 10. The automated electrical wiring system of claim 9, comprising one or more of:

11. The automated electrical wiring system of claim 9 , wherein the monitoring system includes one or more force sensors.

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

13. The at least one wiring arm module includes: a. Rail mounted or b. configured to access the object requiring electrical wiring from the side; c. configured to access the object requiring electrical wiring from above, and d. configured to access said object requiring electrical wiring along a terminal wire port angle; one or more of 2. The automated electrical wiring system according to claim 1.

14. two wiring arm modules cooperate with each other during said manipulation of said wires; a) the two operating wiring arm modules are spaced apart from each other to apply tension to the wires; b. no tension is applied to the portion of the wire not held between the two wiring arm modules; c. one of the two operating wiring arm modules grips the wire and the other of the wiring arm modules slides over the wire to a desired position; d. the wire held without tension is about 1% to about 50% of the total length of the wire; e. the system is configured to monitor the movement of each of the two wiring arm modules; f) the movement is one or more of: movement of one of the two wiring arm modules relative to the other, movement of each of the two wiring arm modules relative to the connector, movement of each of the two wiring arm modules relative to the object, a distance between the two wiring arm modules, and tension in the wire held between the two wiring arm modules; g. the system is configured to modify the movement when a predetermined value is sensed for the movement; 2. The automatic electrical wiring system of claim 1, wherein at least one of the following is true:

15. 10. The automated electrical wiring system of claim 1, further comprising a wire preparation module configured to prepare a wire to be inserted into an object requiring electrical wiring, the wire preparation module providing ready-to-use wire to the at least one wiring arm module.

16. 10. The automated electrical wiring system of claim 1, further comprising the object requiring electrical wiring.

17. the object is an electrical cabinet; the electrical cabinet includes one or more smart components configured to support the electrical wiring; 17. The automated electrical wiring system of claim 16, wherein the one or more smart components are one or more of a smart wire, a smart duct, a latch, a holder, and a marker.

18. 1. A method for automatically connecting at least one wire to at least one connector in a component, comprising: a. automatically grasping a distal end of at least one wire with at least one wire holder; b. automatically moving the at least one wire holder to bring the distal end of the at least one wire closer to the at least one connector; c. automatically inserting the distal end of the at least one wire into the at least one connector; d. automatically evaluating whether said at least one wire is properly connected to said at least one connector; Including, the method further comprising sensing at least one property of the at least one wire associated with the at least one connector during the automatically plugging and the automatically evaluating; The method, wherein sensing at least one property of the at least one wire relative to the at least one connector includes measuring axial and radial forces.

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

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

21. 20. The method of claim 18, wherein the sensing comprises sensing a force applied to the at least one wire as it comes into contact with the at least one connector in the component.

22. two wiring arm modules cooperate with one another in making the connection of the at least one wire, the method further comprising monitoring movement of each of the two wiring arm modules; the movement being one or more of: a movement of one of the two wiring arm modules relative to the other; a movement of each of the two wiring arm modules relative to the connector; a movement of each of the two wiring arm modules relative to the component; a distance between the two wiring arm modules; and a tension in the wire held between the two wiring arm modules; 20. The method of claim 18, further comprising modifying the movement when a predetermined value is sensed for the movement.

23. The method of claim 18, wherein sensing the at least one property of the at least one wire relative to the at least one connector includes monitoring forces in three main directions (F in1 , F in2 , F in3 ) relative to a wiring end effector.

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