Robotic Wire Shuttle Assembly for Variable-Length Raceway Modules
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Solution Overview
Problem
Current methods for assembling electrical raceway modules in end items like airplanes require substantial manual manipulation and result in lengthy processes, non-value-added steps, and significant work-in-process buffers 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
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional manual methods are used to assemble electrical raceway modules, then flexibility in handling wire length variability is maintained, but assembly time increases significantly and productivity decreases
Solution Approach 1:
The patent applies parameter changes by using a wire shuttle subsystem that can dynamically adjust its operation based on wire length. The controller modifies the shuttle's movement parameters (speed, position, timing) to accommodate varying wire lengths, enabling automated handling of length variability without sacrificing productivity. This resolves the contradiction by allowing the system to adapt to different wire parameters while maintaining high-speed automated assembly.
2Productivity
If automated robotic manipulators are used to assemble wires, then productivity increases and manual manipulation is reduced, but the complexity of the assembly system increases
Solution Approach 1:
The patent segments the assembly system into distinct functional modules: a wire shuttle subsystem for wire handling, robotic manipulators for placement, and a controller for coordination. This segmentation allows each component to be optimized independently while working together to achieve high productivity. The modular architecture reduces overall system complexity by making each subsystem manageable and interchangeable.
Solution Approach 2:
The wire shuttle subsystem acts as an intermediary between wire storage and the robotic manipulator. It prepares wires by feeding them to the manipulator in a controlled manner, simplifying the manipulator's task to just placement. This intermediary component reduces the complexity of the overall system by dividing the complex wire handling task into simpler sub-tasks performed by specialized components.
3Productivity
If wires are prepared and assembled in long bundles, then fewer individual assembly operations are needed, but the amount of non-value-added steps (packaging, shipping, receiving) increases
Solution Approach 1:
The patent applies preliminary action by preparing individual wires with connectors attached before assembly into the raceway module. Wires are pre-terminated and staged in the wire shuttle subsystem, ready for immediate installation. This eliminates the need for long-term storage, packaging, and shipping of complete wire bundles, reducing non-value-added time while maintaining efficient assembly operations.
Data Source
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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.