Automatic Electrical Wiring Arms for Fast, Accurate Cabinet Assembly
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Solution Overview
Problem
The process of preparing and wiring electrical cabinets is complex and labor-intensive, requiring efficient systems and methods for automated electrical wiring to improve the generation and manufacture of electrical cabinets.
Innovation Solution
The system employs automated wiring machines with sensors for tactile feedback, AI algorithms for optimization, and deep-learning for component identification, along with robotic manipulators to insert wires accurately into connectors, while managing cable routing and avoiding obstacles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual wiring methods are used, then flexibility and adaptability are maintained, but productivity is low and labor costs are high
Solution Approach 1:
The wiring installation process is divided into distinct segments: panel preparation with pre-marked drill holes, automated drill head positioning and drilling, automated wire routing through guide channels, and automated crimping. Each segment is handled by specialized automated equipment, enabling high-speed installation while maintaining manageable system complexity through functional decomposition
Solution Approach 2:
Pre-fabricated wire harnesses with pre-attached terminals serve as intermediaries between the automated drilling/crimping equipment and the final electrical connections. These standardized harnesses can be prepared offline and simply installed into the automated system, bridging the gap between manual wiring flexibility and automated installation speed
2Reliability
If traditional wiring methods are used, then adaptability to design changes is maintained, but error rates increase and reliability decreases
Solution Approach 1:
Wire harnesses are pre-assembled with pre-attached terminals and pre-routed conductors before installation into the automated system. Drill holes are pre-marked on panels according to the electrical schematic. This preliminary preparation ensures that when components are assembled in the automated system, connections are made precisely according to design specifications, eliminating errors that would require time-consuming detection and correction
Solution Approach 2:
The automated drilling and crimping equipment incorporates sensors and control systems that verify each connection is made correctly according to the electrical schematic. The system can detect and flag errors immediately during assembly, providing real-time feedback that prevents defective products from leaving the manufacturing line
3Ease of manufacture
If skilled technicians perform wiring, then quality is maintained, but labor costs and training requirements increase
Solution Approach 1:
The automated wiring system is designed to be self-guiding through pre-marked drill hole locations, pre-routed wire channels, and pre-positioned components. The equipment automatically positions drill heads, routes wires through guides, and crimps terminals without requiring operator judgment or skill. This enables unskilled or semi-skilled workers to operate the system, dramatically reducing training requirements while maintaining consistent quality
Solution Approach 2:
The automated wiring system is designed as a multi-functional platform that can accommodate different panel types, wire sizes, and connection configurations through programmable control. A single automated system can be reconfigured via software to produce different wiring assemblies, eliminating the need for specialized equipment for each wiring task and simplifying manufacturing operations
Data Source
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AI summary
An aspect of some embodiments of the invention relates to an automatic system for electrical wiring comprising: a wire preparation module; at least one wiring arm module comprising a wiring-end effector at its distal end for manipulating wires to be inserted in an object in need of electrical wiring; and circuitry, which coordinates the operation of said wire preparation module and said at least one wiring arm module using at least one parameter related to said need of electrical wiring.