Automated Wire Contact Insertion with Force and Visual Feedback
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Solution Overview
Problem
Manual insertion of wire contacts into connectors is time-consuming and error-prone, and existing automated systems lack flexibility and often result in improper insertion, requiring costly corrections.
Innovation Solution
A system utilizing a robot with an end-effector and image acquisition devices for automated alignment and insertion of wire contacts, including force feedback and visual feedback for error correction, allowing for flexible connector layouts and automatic error handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated wire contact insertion is implemented, then productivity and assembly speed are improved, but manufacturing precision deteriorates due to improper insertion errors
Solution Approach 1:
The system employs force feedback sensors during insertion to detect when a wire contact is properly seated, and visual feedback cameras to verify insertion depth and orientation. This closed-loop feedback mechanism allows the automated system to detect and correct insertion errors in real-time, maintaining high precision while preserving automation benefits.
Solution Approach 2:
The system performs preliminary alignment operations using vision systems to locate target holes and wire contact positions before insertion. It also conducts preliminary force sensing during the approach phase to anticipate insertion resistance, allowing the system to adjust parameters before actual insertion occurs, thereby preventing errors.
2Loss of time
If automated insertion techniques are used, then loss of time is reduced, but reliability worsens due to improper insertion requiring correction
Solution Approach 1:
Force feedback sensors monitor insertion resistance in real-time to detect proper seating, while visual feedback systems verify insertion quality. This immediate feedback allows the system to confirm successful insertions or detect errors during the process itself, ensuring reliability without requiring post-insertion verification or rework.
Solution Approach 2:
The system performs self-verification of insertion quality through integrated force sensing and vision systems. When improper insertion is detected, the system automatically triggers correction operations, including retracting the wire contact, adjusting positioning, and re-attempting insertion, thereby ensuring reliability autonomously without external intervention.
3Productivity
If wire bundle assembly machines are used, then productivity is improved, but adaptability deteriorates due to restricted connector locations
Solution Approach 1:
The system employs dynamic positioning capabilities where the robot can adapt its approach angles and insertion paths based on the actual connector location and orientation. The vision system dynamically identifies target hole positions, and the control system adjusts motion parameters in real-time, allowing the system to handle various connector layouts and positions while maintaining automated insertion efficiency.
Solution Approach 2:
The system integrates multiple functions into a single automated platform: vision-based location identification, adaptive path planning, force-controlled insertion, and error correction. This multi-functional capability allows the same system to handle diverse connector types, positions, and orientations, providing both high productivity and broad adaptability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables efficient, accurate, and flexible automated insertion of wire contacts into connectors, reducing errors and assembly time while maintaining high precision and adaptability.
Implementation Method 1
control the robot to cease insertion in response to a force between the wire contact and the connector exceeding a predefined value
Implementation Method 2
identify an error condition using visual feedback
Data Source
AI summary
A method, system and computer program product are provided for correction of automated insertion of a wire contact into a target hole of a connector. Methods include controlling a robot having an end-effector to: align the wire contact with the target hole of the connector; advance the wire contact toward and into the target hole of the connector; cease insertion in response to a force between the wire contact and the connector exceeding a predefined value; determining a depth of insertion; in response to the depth of insertion being above a predefined depth, perform a pull test on the inserted wire contact; in response to the depth of insertion being below a predetermined depth, identify an error condition using visual feedback; determine a number of corrective operations performed and perform error correction if the number is below a predefined number, while withdrawing the wire contact otherwise.