Automated Connector Hole Identification via Vision Analysis

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Solution Overview

Problem

Manual insertion of wire ends into wire contact insertion holes of connectors is time-consuming and error-prone, limiting the flexibility of wire bundle assembly machines and increasing assembly costs.

Innovation Solution

A method and system that analyze pixel images of connectors to identify candidate contact insertion holes, consolidate and assign IDs, eliminate outliers, and determine robotic end-effector positions for automated insertion, allowing for flexible connector placement while ensuring accurate connections.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated wire insertion machines are used, then connection time and cost are reduced, but the machines require connectors to be in very restricted and controlled locations, limiting flexibility

Engineering Contradiction:

Improveconnection timeVSAvoidconnector placement flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system dynamically adapts to connector positions by using vision systems to detect and locate connectors in varying locations, then adjusting the robotic end-effector's path in real-time. This allows automated insertion while maintaining flexibility in connector placement, resolving the contradiction between automation and adaptability.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The vision system provides feedback about connector location and orientation, which is used to adjust the insertion process. This closed-loop control enables the system to handle connectors in restricted and controlled locations while maintaining automation, bridging the gap between productivity and flexibility requirements.

Inventive Principle:

Principle #23Feedback

2Adaptability or versatility

If manual wire insertion is used, then connector placement flexibility is maintained, but connection time increases and error rate increases

Engineering Contradiction:

Improveconnector placement flexibilityVSAvoidconnection time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent replaces manual mechanical insertion with an automated robotic system guided by vision technology. This substitution maintains flexibility through adaptive positioning while dramatically reducing connection time and eliminating human error, resolving the contradiction between manual flexibility and automated speed.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If automated wire insertion is used, then connection cost is reduced, but the system complexity increases due to vision systems and robotic control

Engineering Contradiction:

Improveassembly efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The vision system serves multiple functions: locating connectors, verifying insertion accuracy, and guiding the robotic end-effector. This multi-functionality reduces the need for separate systems, thereby managing complexity while maintaining high assembly efficiency and reduced costs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3322048B1Method and system for identifying wire contact insertion holes of a connector

Publication Date: 2021.04.14 THE BOEING CO

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AI summary

A method, system and computer program product are provided for identifying wire contact insertion holes of a connector to facilitate the automated insertion of the wire ends of a wire bundle assembly into the wire contact insertion holes of a connector. In the context of a method, each of a plurality of pixels of an image of the connector is analyzed to identify one or more candidate contact insertion holes for the connector. The method also determines whether the one or more candidate contact insertion holes are to be consolidated and, if so, consolidates the one or more candidate contact insertion holes. The method further includes assigning contact identification numbers of the connector to the one or more candidate contact insertion holes.