Automated Wire Sorting Machine with Vision-Guided Manipulator
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Solution Overview
Problem
The assembly of electrical components with cables is time-consuming due to the manual lacing of wires, which is inefficient and requires human intervention.
Innovation Solution
A wire sorting machine with a camera-guided positioning system and manipulator that automatically sorts and positions wires based on images captured, using a controller to develop a motion profile for precise placement, allowing for automated sorting without human intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual lacing of wires is used, then ease of operation is maintained, but productivity is reduced and loss of time increases
Solution Approach 1:
The system uses vision guidance to automatically detect wire positions, colors, and characteristics, then autonomously plans and executes manipulation sequences without human intervention. The robot manipulator self-adjusts its movements based on real-time camera feedback to position wires correctly
Solution Approach 2:
Manual mechanical wire positioning is replaced with an automated robotic manipulator system guided by vision sensors and controlled by a computer algorithm that plans manipulation sequences, substituting human operators with an automated electromechanical system
2Productivity
If automated wire sorting is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The robot manipulator serves multiple functions: it positions wires, adjusts their orientations, and places them on the circuit board. The vision system performs multiple tasks including detecting wire positions, identifying wire colors, and tracking wire movements throughout the manipulation process
Solution Approach 2:
A computer vision system acts as an intermediary between the robot manipulator and the wires, capturing images, processing visual information, and translating it into manipulation commands. The vision system mediates the interaction between the automated manipulator and the physical wires
3Loss of time
If manual wire positioning is used, then device complexity is low, but loss of time increases
Solution Approach 1:
The system performs automatic wire detection, positioning planning, and manipulation execution without human intervention. The robot manipulator autonomously adjusts wire positions based on vision system feedback, eliminating the need for manual wire lacing operations
Solution Approach 2:
The automated system continuously performs wire detection, manipulation planning, and positioning operations in a seamless workflow. The robot manipulator maintains continuous engagement with the wires, performing multiple positioning adjustments without interruption or manual intervention
Data Source
AI summary
A wire sorting machine includes a frame and a fixture held by the frame. The fixture is configured to support a cable having a plurality of wires. A positioning system is supported by the frame. A guidance system is supported by the positioning system. The guidance system has a camera viewing the fixture that is movable relative to the fixture. A wire manipulator is supported by the positioning system and is moved by the positioning system relative to the fixture. The wire manipulator is configured to engage the wires of the cable to position the wires relative to the fixture. A controller communicates with the positioning system and the guidance system. The controller operates the positing system to control a position of the wire manipulator relative to the fixture based on an image obtained by the camera.