Wire Contact Alignment Using Vision-Guided Connector Hole Detection

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Solution Overview

Problem

Manual insertion of wire ends into connector insertion holes is time-consuming and error-prone, limiting the flexibility of wire bundle assembly machines and increasing costs due to the need for precise and controlled connector placement.

Innovation Solution

A system utilizing a robot with an end-effector equipped with multiple image capture devices and a computing device to detect wire contacts and insertion holes, calculate corrective movements, and align the wire contacts with the appropriate holes, allowing for flexible connector placement and automated insertion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If automated wire insertion machines are used, then productivity and precision are improved, but the connector must be placed in a very restricted and controlled set of locations, reducing adaptability

Engineering Contradiction:

Improvewire insertion speedVSAvoidconnector placement flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The system dynamically adjusts the robot end-effector position based on real-time image processing data. The connector placement locations are not fixed but determined dynamically through image capture and processing, allowing the system to adapt to various connector positions while maintaining automated insertion precision and speed.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent replaces the traditional mechanical positioning system with an optical measurement system. Instead of using fixed mechanical guides and controlled placement locations, the system uses image capture devices and image processing to locate and align wire contacts with connector holes, substituting mechanical constraints with optical field-based positioning.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If manual wire insertion is used, then connector placement flexibility is maintained, but the process is time-consuming and error-prone

Engineering Contradiction:

Improveconnector placement flexibilityVSAvoidwire insertion speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system enables the connector to essentially locate itself through the image capture and processing mechanism. The image processing automatically identifies connector holes and determines the correct alignment positions, allowing the system to adapt to any connector placement while maintaining high automation and speed, eliminating the need for pre-programmed fixed positions.

Inventive Principle:

Principle #25Self-service

3Productivity

If traditional automated insertion machines are used, then insertion speed is improved, but manufacturing precision may be compromised due to restricted positioning requirements

Engineering Contradiction:

Improvewire insertion speedVSAvoidwire contact alignment accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The system implements a feedback loop where image capture devices continuously monitor the position of wire contacts and connector holes, and the image processing unit uses this information to calculate and command corrective movements of the robot end-effector. This closed-loop feedback ensures high alignment precision while maintaining automated insertion speed.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent replaces rigid mechanical positioning systems with a flexible optical measurement and control system. The image-based positioning allows for precise alignment calculations that can accommodate variations in connector placement, achieving high manufacturing precision through computational methods rather than mechanical constraints.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentEP3772786B1Method and system for alignment of wire contact with wire contact insertion holes of a connector

Publication Date: 2024.09.04 THE BOEING CO

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AI summary

A method, system and computer program product are provided for aligning wire contacts with wire contact insertion holes (18) of a connector (10) to facilitate the automated insertion of the wire ends of a wire bundle assembly into the wire contact insertion holes (18) of a connector (10). Methods may include: obtaining captured images from at least two image capture devices (32, 102, 104) attached to an end-effector (100) of a robot (44) of a wire gripper of the end-effector (100); detecting, within at least one image from each of the at least two image capture devices (32, 102, 104), a wire contact; detecting, within at least one image from each of the at least two image capture devices (32, 102, 104), one or more insertion holes (18) of the connector (10); identifying corrective movement for the robot (44) end-effector (100) that aligns a target hole of the one or more insertion holes (18) of the connector (10) with the wire contact; and causing the robot (44) to move the end-effector (100) according to the identified corrective movement.