Robotic Cable Connector Insertion Using Image-Based Alignment
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Solution Overview
Problem
Existing methods for assembling modular cable connectors are labor-intensive and prone to human error, requiring manual insertion of cable insert modules into module retainers.
Innovation Solution
A robotic insertion system is used to automate the assembly process, employing an end effector to hold a cable insert module, capturing images of the module retainer to identify alignment poses, and moving the module from an alignment pose to an insertion pose for precise insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If manual insertion methods are used for assembling modular cable connectors, then operational flexibility is maintained, but labor intensity increases and error rates rise
Solution Approach 1:
The patent replaces manual mechanical insertion operations with an automated robotic system that uses image processing and computer control to guide the insertion process. The robotic arm with end effector automatically positions and inserts cable insert modules into module retainers based on processed image data, eliminating manual labor while maintaining precision through computational guidance rather than complex mechanical guidance systems.
Solution Approach 2:
The system employs image processing algorithms that automatically identify module retainer positions, orientations, and module slot locations from captured images. The robotic system self-corrects for variations in retainer placement and orientation by processing images to determine actual positions versus expected positions, then automatically adjusts insertion parameters without human intervention or complex external guidance infrastructure.
2Productivity
If manual insertion is used, then system simplicity is maintained, but assembly speed decreases and productivity is reduced
Solution Approach 1:
The system captures and processes images of module retainers before the actual insertion operation begins. By pre-identifying retainer positions, orientations, and module slot locations through image processing, the system prepares all necessary alignment data in advance, allowing the robotic insertion to proceed quickly without real-time calculation delays during the critical insertion phase.
Solution Approach 2:
The robotic system maintains continuous operation by seamlessly integrating image capture, image processing, and insertion execution in an automated workflow. The robotic arm continuously moves between picking up cable insert modules and inserting them into retainers, with the controller continuously processing images and adjusting positions, eliminating idle time and maintaining constant productive action throughout the assembly process.
3Manufacturing precision
If manual alignment and insertion are performed, then equipment requirements are minimized, but alignment precision deteriorates
Solution Approach 1:
The patent replaces manual visual alignment operations with an automated image processing system that captures images of module retainers, processes them to identify precise positions and orientations, and uses this data to guide robotic insertion. The system determines alignment parameters computationally from image data rather than relying on manual visual estimation or complex mechanical alignment fixtures, achieving high precision through software-based measurement and control.
4Ease of operation
If automated robotic insertion is implemented, then labor intensity is reduced, but initial system complexity increases
Solution Approach 1:
The robotic insertion system performs self-alignment and self-correction by automatically processing images of module retainers to determine their actual positions and orientations. The system independently calculates alignment parameters, adjusts insertion trajectories, and compensates for variations in retainer placement without requiring complex external guidance systems or extensive programming, making the system easier to operate despite its automated nature.
Solution Approach 2:
The image processing system serves as an intermediary between the robotic arm and the module retainers, translating visual information into precise positioning commands. Rather than requiring direct complex mechanical coupling or elaborate sensor arrays on the robotic arm, the system uses image capture and computational processing as an intermediate step to bridge the gap between the simple robotic manipulator and the varied retainer configurations, simplifying the overall system architecture.
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
In an example, a method (300) for assembly of a modular cable connector (200A) includes, at an end effector (404) of a robotic insertion system (400), holding a cable insert module (406) for insertion into a module slot (418B) of a module retainer (408). Two or more images (500A-C) are captured of the module retainer (408). Image processing is performed to identify a segmented image region (504) corresponding to the module retainer (408) and a virtual plane (506) parallel to a face of the module retainer (408). The end effector (404) is moved to an alignment pose (900) determined based at least in part on the segmented image region (504) and the virtual plane (506). The end effector (404) is moved from the alignment pose (900) toward an insertion pose (902). Upon insertion of the cable insert module (406) into the module slot (418B) of the module retainer (408), the cable insert module (406) is released from the end effector (404).