Wire Routing End Effector for Harness Form Boards
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for assembling wire bundles in aircraft require significant manual setup and programming for each different harness configuration, leading to inefficiencies in robot motion control and increased labor and material costs due to excessive wire length and scrap.
Innovation Solution
A system comprising a manipulator arm with a wire-routing end effector and a robot controller that uses a measurement encoder to learn wire lengths and variations, allowing for automated double-ended wire pre-processing and reduced scrap, and enables rapid development of robot motion controls for routing wires on harness form boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual training or programming is used for each different harness configuration, then the robot can accurately route wires for specific configurations, but the setup time and complexity increase significantly
Solution Approach 1:
The system uses vision sensors to capture images of the form board and automatically generates robot motion paths by copying the visual information. Instead of manual programming, the robot controller processes images to create routing paths, eliminating the need for repetitive manual setup while maintaining routing accuracy.
Solution Approach 2:
The patent replaces manual mechanical programming with an automated vision-based system. The robot controller uses image processing and automatic path generation algorithms to substitute for manual operator programming, reducing both time and complexity while maintaining precision.
2Reliability
If wires are cut with excess length to ensure sufficient material for assembly, then wire availability is guaranteed, but wire scrap and material waste increase
Solution Approach 1:
The system performs preliminary measurement of wire lengths using vision sensors before cutting. By measuring and planning the exact wire length needed in advance, the system cuts wires to precise lengths rather than using excessive material, thereby reducing scrap while ensuring sufficient wire is available for assembly.
Solution Approach 2:
The vision system provides feedback on wire positions and form board configuration, allowing the robot controller to calculate and adjust wire lengths dynamically. This closed-loop approach ensures wires are cut to the exact length needed, minimizing waste while maintaining reliability.
3Manufacturing precision
If customized form boards are used for each wire bundle configuration, then precise wire routing paths are defined, but the time required to set up and change between configurations increases
Solution Approach 1:
The vision-based robot controller serves multiple functions: it captures images, processes form board configurations, generates routing paths, and controls wire cutting and placement. This universal system replaces multiple specialized processes, enabling rapid adaptation to different configurations without requiring physical form board changes, thereby maintaining precision while improving throughput.
Solution Approach 2:
The system dynamically generates routing paths based on real-time image processing rather than using fixed pre-programmed paths. This dynamic adaptation allows the robot to quickly adjust to different wire bundle configurations, maintaining manufacturing precision while significantly reducing setup time and improving overall productivity.
4Ease of manufacture
If double-ended wire processing is performed manually, then wire ends can be prepared separately, but labor costs and assembly time increase
Solution Approach 1:
The robot system merges wire cutting, measurement, and placement operations into a single automated process. By combining these operations that were previously performed separately and manually, the system maintains the flexibility of double-ended processing while dramatically improving productivity and reducing labor costs.
Data Source
AI summary
Methods and apparatus for robot motion control and wire dispensing during automated routing of wires onto harness form boards. The robot includes a manipulator arm and a wire-routing end effector mounted to a distal end of the manipulator arm. The wire-routing end effector is configured for dispensing and routing a wire along a path through form board devices mounted to a harness form board. The wire-routing end effector is moved along a planned path under the control of a robot controller. An end effector path is provided with a set of processes that enable rapid, even fully automatic, development of robot motion controls for routing wires on harness form boards. The system uses a measurement encoder on the end effector that is routing individual wires on a wire harness form board to learn the length of each wire and its length variation.