Cable Wire Insertion Pose Correction Using Force Feedback
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for assembling cable connectors, whether manual or automated, face challenges with inconsistent and time-consuming cable wire insertion due to the variety of shapes and types of connectors, often resulting in misalignments that cause collisions during insertion.
Innovation Solution
A robotic insertion system using an articulated robot arm with an end effector and force sensor to hold a cable wire, initially positioning it based on machine vision and adjusting the pose dynamically based on force feedback to correct misalignments, ensuring accurate insertion into a connector housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated robotic insertion is used to improve consistency and speed, then productivity increases, but misalignment and collision risks increase due to difficulty in detecting and measuring precise insertion poses
Solution Approach 1:
The system employs force feedback during the insertion process to detect misalignment in real-time. When the robotic arm encounters resistance or abnormal forces during insertion, the system adjusts the insertion pose dynamically to correct the misalignment, ensuring accurate placement while maintaining high-speed automated operation.
Solution Approach 2:
The insertion pose is not fixed but dynamically adjusted based on real-time force feedback. The system transitions from a static predetermined insertion path to a dynamic adaptive path that responds to actual insertion conditions, allowing the robotic arm to correct misalignments on-the-fly while maintaining high insertion speed.
2Manufacturing precision
If force feedback is added to detect misalignment, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The robotic arm serves multiple functions: it performs the primary insertion task while simultaneously providing force feedback for alignment detection. This multi-functionality reduces the need for separate sensing systems and complex additional components, thereby improving precision without proportionally increasing overall system complexity.
3Ease of operation
If preliminary insertion pose is predicted using machine vision, then ease of operation improves, but measurement precision may be insufficient leading to misalignment
Solution Approach 1:
The system combines machine vision for preliminary pose prediction with force feedback for real-time verification and correction. The force sensor detects actual insertion conditions and provides feedback to adjust the pose, compensating for any inaccuracies in the vision-based prediction while maintaining ease of automated operation.
Solution Approach 2:
The system performs preliminary pose prediction using machine vision before the actual insertion, establishing an initial insertion path. This preliminary action is then refined through force feedback during the insertion process itself, combining the benefits of automated setup with real-time precision correction.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates consistent and accurate cable wire insertion by dynamically adjusting the insertion pose based on force feedback, reducing collisions and improving efficiency in connector assembly processes.
Implementation Method 1
Using a force sensor, the robotic insertion system detects that a magnitude of an insertion force vector exceeds an insertion force threshold, indicating misalignment of the cable wire relative to the insertion cavity
Data Source
AI summary
A method for assembly of a cable connector includes, an end effector affixed to an articulated robot arm of a robotic insertion system, holding a cable wire for insertion into an insertion cavity of a connector housing. The articulated robot arm is controlled to move the cable wire toward a preliminary insertion pose predicted to correspond to insertion of the cable wire into the insertion cavity. Using a force sensor, the robotic insertion system detects that a magnitude of an insertion force vector exceeds an insertion force threshold, indicating misalignment of the cable wire relative to the insertion cavity. The articulated robot arm is controlled to move the cable wire toward a corrected insertion pose determined based at least in part on the insertion force vector, wherein the preliminary insertion pose and the corrected insertion pose differ by a pose adjustment.