Humanoid Robot Wiring Assembly With Through-Bore Routing
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Solution Overview
Problem
Conventional humanoid robot wiring assemblies are bulky, restrict motion, prone to mechanical stress and environmental damage, and compromise signal integrity, making them unsuitable for complex, dynamic environments and increasing maintenance needs.
Innovation Solution
An advanced wiring assembly for humanoid robots featuring internal through-bore wiring and flattened actuator bundle portions, secured by strain relief members, which minimizes bulk, protects conductors, and ensures robust signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional wiring assemblies are used in humanoid robots, then electrical connections are established, but the wiring becomes bulky and restricts robot motion
Solution Approach 1:
The wiring assembly is segmented into modular connectors that can be independently positioned and connected. This segmentation allows the wiring to be distributed along the robot's limbs rather than concentrated in bulky bundles, reducing restriction on joint motion while maintaining electrical connectivity.
Solution Approach 2:
The wiring transitions from a two-dimensional surface-level arrangement to a three-dimensional integrated structure embedded within the robot's limb architecture. Wires are routed through internal channels and cavities, utilizing the third dimension to eliminate external bulk while preserving motion freedom.
2Reliability
If conventional wiring assemblies are used, then electrical connections are made, but the wires are prone to mechanical stress and environmental damage
Solution Approach 1:
The wiring assembly employs a nested structure where individual wires are insulated, then grouped into sub-bundles, which are further enclosed within protective conduits and structural housings. This multi-layer nesting protects wires from mechanical stress and environmental factors while maintaining compact integration.
Solution Approach 2:
The design incorporates pre-positioned strain relief features, flexible conduits, and shock-absorbing mounting structures that cushion the wiring against mechanical stress before it occurs. These protective elements are built into the assembly during manufacturing, preventing damage from subsequent operational stresses.
3Reliability
If conventional wiring assemblies are used, then power and signals are transmitted, but signal integrity is compromised
Solution Approach 1:
Different portions of the wiring assembly have differentiated properties: high-frequency signal wires are shielded with metallic braiding and positioned away from high-current power conductors, while power wires use thicker insulation. This local quality differentiation minimizes electromagnetic interference and maintains signal integrity in specific critical zones.
4Ease of manufacture
If conventional wiring assemblies are used, then electrical connections are established, but assembly and maintenance become complex
Solution Approach 1:
Wiring harnesses are pre-assembled and pre-tested as complete modules during manufacturing, with connectors pre-positioned and routed through fixed channels. This preliminary action transfers complexity from the field assembly stage to the controlled manufacturing environment, simplifying robot assembly and maintenance while maintaining connection reliability.
Data Source
AI summary
Various advanced wiring assemblies for a humanoid robot are disclosed. The wiring assembly includes a first actuator printed circuit board (PCB) positioned near a first side of a first actuator and including a first PCB terminal. A second side of the first actuator includes: an output, an actuator cover coupled to the output and having a wire bundle opening formed therein, and an actuator opening formed through an extent of the second side. The wiring assembly includes a wire bundle having: a first end connector coupled to the first PCB terminal, a second end connector coupled to the second PCB terminal, and a plurality of wires that extend between the first end connector and the second end connector, and wherein said plurality of wires extends through the actuator opening of the second side of the first actuator and the wire bundle opening formed in the actuator cover.