Robotic Cable Sequence Separation for Switchgear Wiring
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Solution Overview
Problem
The complexity of switchgear construction, particularly in automating the wiring of electronic components with diverse cable requirements, limits the use of conventional automatic wiring devices and necessitates a method for fully automated wiring that accounts for component tolerances and variations.
Innovation Solution
A method involving a cable sequence where prefabricated cables are connected to form a chain, with a multifunctional end effector for identification, localization, and separation of cables, allowing robotic control based on a circuit diagram to ensure precise wiring, including mechanical and electrical testing, and a mobile workpiece carrier for efficient handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If cable sequences with pre-assembled cables are used to reduce complexity, then the number of cable handling operations decreases, but compatibility with common wiring machines is lost
Solution Approach 1:
The system segments the wiring process into distinct phases: cable sequence preparation, robotic separation, and electrical connection. The cable sequence is divided into individual cables by the robot at connection points, allowing pre-assembly benefits while maintaining machine compatibility through standardized end-effectors.
Solution Approach 2:
A robotic system acts as an intermediary between the cable sequence and traditional wiring machines. The robot separates cables from the sequence and positions them for connection, bridging the gap between the innovative cable sequence format and existing wiring infrastructure.
2Productivity
If conventional automatic wiring devices are used, then wiring speed is maintained, but they cannot handle diverse cable requirements and component variations
Solution Approach 1:
The system transitions from static, fixed wiring machines to a dynamic robotic system that can adapt its movements and actions. The robot adjusts cable separation points, routing paths, and connection positions based on real-time component locations and cable requirements, maintaining speed through programmable automation.
Solution Approach 2:
The system changes operational parameters dynamically - cable length, routing direction, separation points - based on the specific wiring task. The robotic system modifies these parameters in real-time to handle diverse cable requirements while maintaining automated wiring speeds.
3Ease of manufacture
If component positions are fixed according to initial data, then wiring planning is simplified, but manufacturing tolerances cause position deviations
Solution Approach 1:
The system implements feedback through optical sensors that detect actual component positions on the mounting plate. This position data is fed back to the control system, which adjusts the wiring plan and robot movements to accommodate tolerances, maintaining both planning simplicity and positioning accuracy.
Solution Approach 2:
The system performs preliminary detection of component positions before wiring begins. By identifying and localizing components in advance, the system prepares adjusted wiring paths and connection points that account for manufacturing tolerances, ensuring accurate connections without complicating the overall wiring plan.
Data Source
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AI summary
The invention relates to a method for the electrical cabling of electronic components (5) in switchgear construction, said method comprising the following steps: a. providing (100) a plurality of electronic components (5), which are mounted on a common workpiece (1), more particularly on a mounting plate; b. cabling (200) the electronic components (5) using a robot (2) in accordance with a predefined connection plan and in a predefined sequence, wherein a cable sequence (3) of prefabricated cables is supplied to the robot (2) and the cables are arranged in the cable sequence (3) in the predefined order; wherein the cabling (200) comprises gripping (201) a free cable end of the cable sequence (3) with a multifunctional end effector (4) of the robot (2), supplying (202) the free cable end to an electric connection of one of the electronic components (5) with the multifunctional end effector (4) and removing (203) the cable from the cable sequence (3) with a separating unit of the multifunctional end effector (4). The method can also comprise laying a cable of the cable sequence in a cable channel, bringing a cable of the cable sequence into contact with a conductor connection terminal and/or mechanically and/or electrically checking an established contact. The invention further describes a corresponding arrangement.