Robotic Wire Connector Assembly with Wire Separation and Vision Alignment
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Solution Overview
Problem
Existing automated wire bundle assembly systems require specific connector layouts and are prone to errors when inserting multiple wires, leading to inefficiencies and increased costs due to manual intervention.
Innovation Solution
A system utilizing a robot end-effector with cameras and a separator device to identify and align wire contacts with insertion holes in arbitrary order, overcoming obstructions from previously inserted wires by separating them to ensure accurate insertion.
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 very restricted and controlled connector locations, limiting flexibility and adaptability
Solution Approach 1:
The patent implements a dynamic robotic system with multi-axis movement capability that can adapt to connectors in various positions and orientations. The robot arm can dynamically adjust its position and the end effector can orient itself to match the connector's location, eliminating the need for restricted connector placements while maintaining automated assembly speed.
Solution Approach 2:
The robotic system is designed with universal applicability to handle connectors in arbitrary positions and orientations. The combination of robot arm positioning and end effector orientation capabilities creates a multi-functional system that can accommodate various connector layouts without requiring reconfiguration, thus improving both productivity and adaptability.
2Loss of time
If automated wire insertion techniques are used, then assembly time is reduced, but the system may improperly insert wire contacts, requiring correction and halting the process
Solution Approach 1:
The patent incorporates vision systems and sensors that provide real-time feedback on wire contact position, connector hole location, and alignment status. This feedback loop allows the robotic system to detect and correct positioning errors before insertion, ensuring high reliability while maintaining automated assembly speed.
Solution Approach 2:
The system performs preliminary alignment and verification actions before the actual wire contact insertion. The robot positions the wire contact and the end effector orients itself in advance, with verification steps to ensure proper alignment, preventing improper insertions before they occur.
3Adaptability or versatility
If manual wire insertion is used, then flexibility in connector presentation is maintained, but the process is time-consuming and error-prone
Solution Approach 1:
The robotic system with its advanced positioning and orientation capabilities effectively serves itself by automatically adapting to various connector presentations without human intervention. The system can independently handle flexible connector layouts while maintaining high assembly speed, eliminating the trade-off between flexibility and productivity.
4Device complexity
If manual wire insertion is used, then no additional equipment complexity is introduced, but the process is error-prone and increases assembly cost
Solution Approach 1:
The patent replaces manual mechanical insertion with an automated robotic system equipped with precision positioning, vision systems, and intelligent control. This substitution eliminates human error while the modular robotic design keeps the added complexity manageable, improving reliability without excessive complexity.
Data Source
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AI summary
A method, system and computer program product are provided for an automated insertion of a wire contact into an insertion hole of a connector. The method includes: 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.