Split Funnel Wire Insertion Prevents Shielding Dislocation
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Solution Overview
Problem
Automated wire assembly systems are impractical for fabricating aircraft wiring harnesses due to the need for high reliability and precise handling of high-quality components, particularly in preventing dislocation of shielding during wire insertion into solder sleeves.
Innovation Solution
An apparatus and method using an end effector with solder sleeve grippers and slug puller grippers that move independently to hold and position a wire surrounded by shielding, utilizing a split funnel to insert the wire into a solder sleeve without dislocating the shielding, and then removing the slug to secure the wire in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manual assembly methods are used to ensure high reliability and prevent shielding dislocation, then assembly quality is maintained, but productivity is low and labor costs are high
Solution Approach 1:
The system uses vision guidance to automatically detect wire positions and characteristics, with the robot autonomously adjusting its motion trajectory and gripper positioning without human intervention, achieving both high reliability through precise detection and high productivity through automated execution
Solution Approach 2:
The patent replaces manual mechanical assembly with an automated robot system that integrates vision sensing, intelligent decision-making, and precise motion control, eliminating manual labor while maintaining assembly quality through automated precision handling
2Productivity
If automated assembly systems are implemented to increase productivity, then production efficiency improves, but reliability decreases due to difficulty in preventing shielding dislocation
Solution Approach 1:
The vision system acts as an intermediary between the robot and the wire assembly, providing real-time detection and feedback that enables the automated system to perceive and respond to shielding position, ensuring reliable assembly while maintaining high productivity through automated operation
Solution Approach 2:
The system dynamically adjusts motion parameters such as speed, acceleration, and gripper force based on real-time vision detection of wire characteristics and shielding position, enabling precise control that prevents shielding dislocation while maintaining efficient automated production
3Manufacturing precision
If precision handling is used to prevent shielding dislocation, then assembly quality improves, but device complexity increases
Solution Approach 1:
The robot system performs multiple functions including wire detection, trajectory planning, gripper control, and precision positioning within a single integrated platform, achieving high manufacturing precision without proportionally increasing device complexity through multi-functional design
Data Source
AI summary
Systems and methods are provided for wire processing. In certain examples, a wire processing system is disclosed. The wire processing system includes an electrical wire and solder sleeve joining system. The electrical wire and solder sleeve joining system includes an end effector configured to hold a solder sleeve and a split funnel configured to guide insertion of wire into the solder sleeve, allow movement of the solder sleeve through the split funnel in a second position, and prevent movement of the solder sleeve through the split funnel in a first position. The end effector can additionally be configured to remove a slug from the wire.