Electrical Raceway Wire Assembly for Variable-Length Automation

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Solution Overview

Problem

Current methods for assembling electrical raceways in end items like airplanes require substantial manual manipulation and result in lengthy processes, significant work-in-process buffers, and non-value-added steps due to scarce resources and long lead items, with no effective solutions for managing wire length variability.

Innovation Solution

A wire assembly system utilizing robotic manipulators and a wire shuttle subsystem to autonomously assemble electrical raceway modules, including a raceway assembly fixture, a wire shuttle subsystem, and a system controller to control the placement of wires into predetermined locations within the raceway assembly fixture.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If traditional manual methods are used to assemble electrical raceways, then flexibility in handling wire length variability is maintained, but assembly time increases significantly and productivity decreases

Engineering Contradiction:

Improvehandling wire length variabilityVSAvoidassembly time

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The wire assembly process is segmented into discrete operations: wire feeding, positioning, termination, and assembly. Each operation is performed by specialized automated components (wire feeders, robotic manipulators, positioning devices) that can independently handle variations in wire length through programmable control, thereby maintaining adaptability while dramatically improving productivity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system employs dynamic positioning mechanisms and adjustable wire feeders that can adapt in real-time to different wire lengths. The robotic manipulators feature programmable motion paths and force control that allow them to accommodate varying wire dimensions, enabling automated high-speed assembly without sacrificing flexibility.

Inventive Principle:

Principle #15Dynamics

2Productivity

If automated robotic systems are implemented to reduce manual labor, then productivity increases and assembly time shortens, but device complexity increases

Engineering Contradiction:

Improveassembly timeVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The robotic system is designed with multi-functional components that perform multiple operations. The robotic manipulators can execute wire handling, positioning, and assembly tasks. The control system integrates wire length measurement, positioning calculation, and robotic motion control into a unified platform, reducing overall system complexity despite the high productivity gains.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

A centralized control system acts as an intermediary between the various automated components (wire feeders, robotic manipulators, positioning devices). This mediator coordinates their operations, manages wire length variability, and simplifies the interaction between complex subsystems, thereby managing device complexity while maintaining high productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If traditional processes with multiple non-value-added steps are used, then resource allocation flexibility is maintained, but loss of time increases due to packaging, shipping, and unpackaging

Engineering Contradiction:

Improveresource allocation flexibilityVSAvoidtime for packaging, shipping, unpackaging

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system merges wire preparation, termination, and assembly operations into a single integrated automated process. Wires are fed directly from storage into the assembly fixture without intermediate packaging, shipping, or unpackaging steps. This consolidation eliminates non-value-added time losses while maintaining resource allocation flexibility through programmable control.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Wires are pre-positioned and pre-measured in the automated system before assembly begins. The system calculates required wire lengths and positions them in advance, eliminating the need for post-assembly adjustments and reducing overall process time. This preliminary action approach maintains flexibility by allowing programmatic adjustment of wire specifications.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20250323475A1Wire assembly systems and methods for assembling electrical raceway modules

Publication Date: 2025.10.16 THE BOEING CO

AI summary

A wire assembly system for assembling an electrical raceway module includes a raceway assembly fixture, a wire shuttle subsystem, at least one robotic manipulator and a system controller. A method for assembling an electrical raceway module includes receiving the raceway assembly fixture from a raceway preparation area on a workpiece support structure and receiving a wire for placement in the raceway assembly fixture from a wire preparation system. The wire is positioned on an upper surface of the tool support structure between a shuttle holding a first terminated end and another shuttle holding the other terminated end. The wire is picked from the upper surface of the tool support structure, the first shuttle and the second shuttle and placed at a predetermined location in the raceway assembly fixture. The process can be repeated for additional wires until the electrical raceway module is assembled.