Abstract: Methods and apparatus for automated routing of wires of a wire harness on a form board. A wire harness comprising a wire end connector and a multiplicity of groups of wires is supported and carried by a carrier end effector mounted to an end of a first robotic arm. The wire groups are accessed and then routed on the form board by a routing end effector mounted to an end of a second robotic arm. Initially a wire gripper of the routing end effector is opened. The second robotic arm is then controlled to move the routing end effector so that respective first portions of all wire groups are accessible for gripping by the wire gripper. Then the wire gripper is closed to grip the first portions of wires. Then the second robotic arm is controlled to move the routing end effector to place second portions of the wires of all wire groups in a first elastic retainer wire routing device attached to the form board.

Abstract: A dimmable window system includes a reveal retaining a window, a dimmable member, and an energy harvester configured to harvest energy to provide power to the dimmable member and other components of the dimmable window system. The dimmable window system can be configured for a vehicle, such as an aircraft.

Abstract: A method for cable wire insertion monitoring includes receiving, from a camera system, an inspection image of a connector housing held in a housing retainer of a housing inspection system. Insertion of a cable wire into a corresponding cable cavity of the connector housing is detected via an insertion monitoring machine vision system. Based at least in part on the inspection image, an insertion depth of the cable wire into the corresponding cable cavity is estimated. An indication of the insertion depth of the cable wire is output.

Abstract: A wire assembly system for assembling an electrical raceway module includes a raceway assembly fixture, a wire shuttle subsystem, at least one robotic manipulator and a system controller. A method for assembling an electrical raceway module includes receiving the raceway assembly fixture from a raceway preparation area on a workpiece support structure and receiving a wire for placement in the raceway assembly fixture from a wire preparation system. The wire is positioned on an upper surface of the tool support structure between a shuttle holding a first terminated end and another shuttle holding the other terminated end. The wire is picked from the upper surface of the tool support structure, the first shuttle and the second shuttle and placed at a predetermined location in the raceway assembly fixture. The process can be repeated for additional wires until the electrical raceway module is assembled.

Abstract: A wire carrier for transporting a wire includes a support structure, a coil holder, a first end holder and a second end holder. An end effector for transporting the wire includes a support structure, a first retaining device, a second retaining device, a third retaining device and an interface member. A method for transporting the wire includes transporting the wire from a wire preparation system to a wire assembly system using a wire carrier on a wire transport system. The wire includes first and second ends. The wire preparation system formed the wire in a coil with a breakout length between the coil and the first end and another breakout length between the coil and the second end. The method also includes transferring the coil with the first and second ends from the wire carrier on the wire transport system to the wire assembly system using an electro-mechanical manipulator.

Abstract: Methods and apparatus for automated routing of wires of a wire harness on a form board. A wire harness comprising a wire end connector and a multiplicity of groups of wires is supported and carried by a carrier end effector mounted to an end of a first robotic arm. The wire groups are accessed and then routed on the form board by a routing end effector mounted to an end of a second robotic arm. Initially a wire gripper of the routing end effector is opened. The second robotic arm is then controlled to move the routing end effector so that respective first portions of all wire groups are accessible for gripping by the wire gripper. Then the wire gripper is closed to grip the first portions of wires. Then the second robotic arm is controlled to move the routing end effector to place second portions of the wires of all wire groups in a first elastic retainer wire routing device attached to the form board.

Abstract: An automated apparatus for installing a sleeve on a cable includes a split funnel assembly, a cable feeding mechanism, a robot comprising a robot tool mounting flange and a plurality of robot motors, a sleeve gripper mounted to the robot tool mounting flange, a plurality of heaters, and a computer configured to output commands in accordance with a predetermined computer program. The split funnel assembly includes an actuator and a split funnel comprising a pair of funnel halves which are able to open and close in response to activation of the actuator. Each funnel half comprises a cable guide channel and a funnel extension. While the split funnel is in the funnel closed state, the funnel extensions form a seat for the sleeve and the cable guide channels form a repeatable path for the cable to follow through the funnel. The apparatus further includes a cable centering gripper, a cable clamp assembly, a slug puller assembly, and a ground lead management system.

Abstract: In an example, a method for assembly of a modular cable connector includes, at an end effector of a robotic insertion system, holding a cable insert module for insertion into a module slot of a module retainer. Two or more images are captured of the module retainer. Image processing is performed to identify a segmented image region corresponding to the module retainer and a virtual plane parallel to a face of the module retainer. The end effector is moved to an alignment pose determined based, at least in part, on the segmented image region and the virtual plane. The end effector is moved from the alignment pose toward an insertion pose. Upon insertion of the cable insert module into the module slot of the module retainer, the cable insert module is released from the end effector.

Abstract: A cable connector assembly includes a module retainer and a set of two or more cable insert modules sized and shaped for removable retention within two or more module slots of the module retainer. A cable insert module of the set of two or more cable insert modules includes a cable insertion recess sized and shaped for insertion of a cable wire of a cable, a connectivity interface on an opposing face of the cable insert module, and a transmission path between the cable insertion recess and the connectivity interface.

Abstract: A method for automated cable wire processing includes receiving a set of two or more cable wires, including at least a first cable wire positioned at a selection position, and a second cable wire positioned away from the selection position. A cable selection tool is automatically moved to contact the set of two or more cable wires, such that contact between the cable selection tool and the first cable wire causes a tip portion of the first cable wire to extend into a working region, and contact between the cable selection tool and the second cable wire moves a tip portion of the second cable wire outside of the working region. One or more tip processing operations are applied to the tip portion of the first cable wire within the working region.

Abstract: A method, system and computer program product are provided for determining wire contact insertion based on image analysis. Methods include: acquiring at least one image of a connector having a plurality of wire contact insertion holes; identifying a wire contact within a wire contact insertion hole of the plurality of wire contact insertion holes; determining that the wire contact insertion hole is a correct wire contact insertion hole; determining that the wire contact has been fully inserted into the correct wire contact insertion hole; and providing feedback indicating that the wire contact is fully inserted into the correct wire contact insertion hole. The feedback includes in some cases a first indicator indicating that the wire contact is in the correct wire contact insertion hole and a second indicator indicating that the wire contact is fully inserted into the correct wire contact insertion hole.

Abstract: A system includes one or more distribution nozzles associated with a seat within an internal space, and a return air grill associated with the seat. Airflow is directed from the one or more distribution nozzles toward and into the return air grill. A method includes associating one or more distribution nozzles with a seat within an internal space, associating a return air grill with the seat, and directing airflow from the one or more distribution nozzles toward and into the return air grill.

Abstract: Systems and methods for automated wire pickup using image-based robot guidance. The machine vision-based system includes: a robot arm; a tool head coupled to the distal end of the robot arm and including a wire gripper motor; a wire gripper movably coupled to the tool head and operatively coupled to the wire gripper motor; a wire holder configured for clamping a wire; camera means mounted to the distal end of the robot arm and having first and second fields of view which intersect in a volume of space that includes the tip of the wire gripper and the wire holder; and a computer system configured to control operation of the robot arm motors and wire gripper motor. More specifically, the computer system is configured for visually estimating the position and orientation of a contact-equipped wire being held by the wire holder and then generating robot guidance to enable automated pickup of the end section of the wire by the wire gripper.

Abstract: A method, system and computer program product are provided for automated insertion of a wire contact into an insertion hole of a connector. Methods include: controlling a robot having an end-effector to position a wire contact proximate to a connector using a wire gripper and a separator device of the end-effector; controlling the robot to advance the separator device between two or more wires previously connected to the connector; controlling the robot to align the wire contact with a insertion hole of the connector; controlling the robot to advance the wire contact toward the insertion hole of the connector and at least partially insert the wire contact into the insertion hole; controlling the robot to release the wire contact from the wire gripper; and controlling the robot to withdraw the wire gripper and the separator device from between the two or more wires previously connected to the connector.

Abstract: Systems and methods for automated wire pickup using image-based robot guidance. The machine vision-based system includes: a robot arm; a tool head coupled to the distal end of the robot arm and including a wire gripper motor; a wire gripper movably coupled to the tool head and operatively coupled to the wire gripper motor; a wire holder configured for clamping a wire; cameras mounted to the distal end of the robot arm and having first and second fields of view which intersect in a volume of space that includes the tip of the wire gripper and the wire holder; and a computer system configured to control operation of the robot arm motors and wire gripper motor. More specifically, the computer system is configured for visually estimating the position and orientation of a contact-equipped wire being held by the wire holder and then generating robot guidance to enable automated pickup of the end section of the wire by the wire gripper.

Abstract: Methods and apparatus for automated routing of wires of a wire harness on a form board. A wire harness comprising a wire end connector and a multiplicity of groups of wires is supported and carried by a carrier end effector mounted to an end of a first robotic arm. The wire groups are accessed and then routed on the form board by a routing end effector mounted to an end of a second robotic arm. Initially a wire gripper of the routing end effector is opened. The second robotic arm is then controlled to move the routing end effector so that respective first portions of all wire groups are accessible for gripping by the wire gripper. Then the wire gripper is closed to grip the first portions of wires. Then the second robotic arm is controlled to move the routing end effector to place second portions of the wires of all wire groups in a first elastic retainer wire routing device attached to the form board.

Abstract: Methods and apparatus for automated routing of wires of a wire harness on a form board. A wire harness comprising a wire end connector and a multiplicity of groups of wires is supported and carried by a carrier end effector mounted to an end of a first robotic arm. The wire groups are accessed and then routed on the form board by a routing end effector mounted to an end of a second robotic arm. Initially a wire gripper of the routing end effector is opened. The second robotic arm is then controlled to move the routing end effector so that respective first portions of all wire groups are accessible for gripping by the wire gripper. Then the wire gripper is closed to grip the first portions of wires. Then the second robotic arm is controlled to move the routing end effector to place second portions of the wires of all wire groups in a first elastic retainer wire routing device attached to the form board.

Abstract: A system for processing a cable end of a cable. The system includes: a pallet delivery system; a cable processing module; a pallet supported by the pallet delivery system; an on-pallet dual-belt cable feed mechanism configured for linear feeding of the cable end into the cable processing module; and an off-pallet electric motor operatively coupled for driving circulation of a pair of belts of the dual-belt cable feed mechanism. The cable processing module includes cable processing equipment configured to perform an operation on the cable end and a computer.

Abstract: An electrical contact system includes a contact having a barrel with a wire entry portion having a first diameter, a clip portion having a second diameter, and a cam portion having a second diameter at a first end that tapers to a third diameter at a second end near the wire entry portion. The system also includes a clip positioned in the clip portion of the barrel, wherein ends of inwardly directed tines of the clip are configured to engage the conductor to enable the clip to be drawn onto the cam portion in response to a user pulling the wire after insertion of the conductor through the clip.

Abstract: Thermal control system for aircraft main landing gear wheel wells and related methods are disclosed. An example thermal control system includes a conduit defining a fluid passageway between an inlet and an outlet. The inlet of the conduit positioned in fluid communication with a landing gear wheel well and the outlet of the conduit positioned in fluid communication with the atmosphere. The conduit generates a pressure differential through the fluid passageway between the inlet and the outlet to exhaust heat from the landing gear wheel well to the atmosphere.