Robotic Wire Connector Assembly with Wire Separation Feedback
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Solution Overview
Problem
Manual wire connector assembly is time-consuming and error-prone, especially with wire bundles containing dozens or hundreds of wires, and existing automated systems require rigid connector placement, limiting flexibility and often result in improper insertions.
Innovation Solution
A system and method using a robot with an end-effector equipped with a wire gripper and separator device, controlled by a computing device to align and insert wire contacts into designated holes in arbitrary order, overcoming obstructions from previously connected wires by using cameras for feedback and a separating mechanism to create a clear path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated wire insertion techniques are used, then assembly speed and productivity are improved, but the system requires rigid connector placement and limited flexibility
Solution Approach 1:
The system employs a robotic arm with multiple degrees of freedom that can dynamically adjust its position and orientation to accommodate connectors in various locations. The robot's movable end effector with separator device can adapt its configuration based on the specific insertion task, providing both automated speed and placement flexibility.
Solution Approach 2:
A separator device acts as an intermediary between the wire gripper and the connector. This separator temporarily moves wires out of the way during insertion and then restores them to their original positions, enabling automated insertion without requiring rigid connector placement while maintaining wire bundle integrity.
2Loss of time
If automated wire insertion techniques are used, then assembly time is reduced, but improper insertions may occur halting the process
Solution Approach 1:
The system incorporates cameras that capture images of the connector and wire contacts during the insertion process. This visual feedback allows the control system to verify proper alignment and insertion, detecting improper insertions and preventing process halts while maintaining high assembly speed.
Solution Approach 2:
The separator device performs preliminary action by moving wires out of the way before insertion occurs. This pre-positioning ensures clear access to insertion holes and proper wire alignment, preventing improper insertions that would halt the automated process.
3Adaptability or versatility
If wires are manually inserted into connector holes, then flexibility in insertion order is maintained, but the process is time-consuming and error-prone
Solution Approach 1:
The separator device serves as a mediator that enables arbitrary insertion orders by temporarily clearing the insertion path for each wire contact. It moves wires out of the way during insertion and restores them afterward, providing manual-like flexibility at automated speeds.
Solution Approach 2:
The robotic system dynamically adapts its insertion sequence based on real-time conditions and wire bundle configuration. The controller can determine optimal insertion orders automatically, providing flexibility comparable to manual assembly while maintaining high productivity through automation.
Data Source
AI summary
A method, system and computer program product are provided for automated insertion of a wire contact into an insertion hole of a connector. Methods include: controlling a robot having an end-effector to position a wire contact proximate to a connector using a wire gripper and a separator device of the end-effector; controlling the robot to advance the separator device between two or more wires previously connected to the connector; controlling the robot to align the wire contact with a insertion hole of the connector; controlling the robot to advance the wire contact toward the insertion hole of the connector and at least partially insert the wire contact into the insertion hole; controlling the robot to release the wire contact from the wire gripper; and controlling the robot to withdraw the wire gripper and the separator device from between the two or more wires previously connected to the connector.