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.

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: 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: Systems and methods for designing and assembling form boards with attached wire routing devices for use in wire bundle assembly. The assembly method comprises: (a) establishing a coordinate system of a form board having a multiplicity of holes; (b) using a computer system to determine locations of form board devices of different types with reference to the coordinate system of the form board based on engineering data specifying a wire bundle configuration; and (c) fastening the form board devices of different types to respective holes of the form board having centers closest to respective locations determined in step (b). The form board devices may be inserted robotically or manually.

Abstract: An automated wire insertion machine for inserting wires into grommet cavity locations of an electrical connector includes a controllable wire insertion robot and a processor to generate pre-generated plug maps based upon an original plug map of the grommet cavity locations and to control the wire insertion robot based upon one pre-generated plug map to insert the wires into the grommet cavity locations. The pre-generated plug maps are generated by defining a range of potential error of the grommet cavity locations that includes at least one of a potential rotational error and a potential translational error, defining an acceptable tolerance of the grommet cavity locations that includes at least one of an acceptable rotational tolerance and an acceptable translational tolerance, and calculating offset values of the grommet cavity locations based on the range of potential error and the acceptable tolerance, thereby generating the plurality of pre-generated plug maps.

Abstract: A method utilizes a funnel system and robotic end effector grippers to feed an unjacketed portion of a shielded cable through a sleeve. The funnel is designed with one or more thin extensions (hereinafter “prongs”) on which a sleeve is placed prior to a cable entering the funnel. Preferably two or more prongs are employed, although a single prong may be used if properly configured to both guide a cable and fit between the sleeve and cable. The prongs close off the uneven surface internal to a sleeve and provide a smooth surface for the cable to slide along and through the sleeve, preventing any damage to the exposed shielding. The sleeve is picked up and held on the prongs using a robotic end effector. If the sleeve is a solder sleeve, the robotic end effector has grippers designed to make contact with the portions of the solder sleeve that are between the insulating rings and the central solder ring.

Abstract: Methods and apparatus for temporarily holding one end of a wire on a harness form board during automated transfer from one robot to another robot. The apparatus includes a wire holding device which is designed to facilitate the transfer of a wire end from a first end effector of a first robot to a second end effector of a second robot. The wire holding devices have different structures, but share the common feature that opening of the wire holding device (to enable wire insertion) involves applying a contact force which overcomes a spring force that urges the wire holding device to be closed. The end effectors are designed and their movements are controlled in a manner such that the moving end effector applies the contact force necessary to overcome the closure-inducing spring force being exerted.

Abstract: Systems and methods for designing and assembling form boards with attached wire routing devices for use in wire bundle assembly. The assembly method comprises: (a) establishing a coordinate system of a form board having a multiplicity of holes; (b) using a computer system to determine locations of form board devices of different types with reference to the coordinate system of the form board based on engineering data specifying a wire bundle configuration; and (c) fastening the form board devices of different types to respective holes of the form board having centers closest to respective locations determined in step (b). The form board devices may be inserted robotically or manually.

Abstract: A wire guide and a laser wire-processing device that includes a wire guide are provided. The laser wire-processing device includes a housing and an aperture in a side of the housing, wherein the aperture defines a longitudinal axis that is substantially perpendicular to the aperture. The laser wire-processing device also includes a backstop arranged in the housing and aligned with the longitudinal axis, the backstop defining a wire-contact surface in a facing relationship with the aperture. The laser wire-processing device also includes a wire guide arranged in the housing to manipulate a wire inserted through the aperture into a desired position relative to the longitudinal axis between the aperture and the backstop. The laser wire-processing device also includes a laser operable to direct a laser beam toward an insulation layer of the wire. The wire guide could be a tube arranged in the device or a backstop guide.

Abstract: 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.

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: Systems and methods are provided for wire processing. In certain examples, a wire processing system is disclosed. The wire processing system includes an electrical wire and solder sleeve joining system. The electrical wire and solder sleeve joining system includes an end effector configured to hold a solder sleeve and a split funnel configured to guide insertion of wire into the solder sleeve, allow movement of the solder sleeve through the split funnel in a second position, and prevent movement of the solder sleeve through the split funnel in a first position. The end effector can additionally be configured to remove a slug from the wire.

Abstract: A method of reducing entanglement of wires includes receiving, at a tray, one or more first wires of a first wire group from a wire feed system of a wire processing machine. In addition, the method includes receiving, at the tray, one or more second wires of a second wire group from the wire feed system after receiving the first wire group at the tray. The method further includes physically separating, using a separator device associated with the tray, at least a portion of the first wire group from the second wire group. The method also includes moving the second wire group relative to the first wire group, reducing movement of at least a portion of the first wire group relative to a tray surface during movement of the second wire group relative to the first wire group.

Abstract: A shield trim is performed by tearing bunched shield strands circumferentially along a circular edge. The apparatus includes a pair of aligned metal plates that have been drilled through multiple times such that holes of varying diameters pass through both plates. A cable gripper on the entry side of the device clamps the cable in place. A shield gripper on the rear side of the device closes over the exposed shielding of the cable, and the two plates are pushed together. The shield gripper travels with the rear plate, pushing the shield over the wires and causing the shield to bunch between the two plates. With the two plates pushed together, both grippers open and the cable is pulled free from the device. This pull forces a stress concentration which tears the shield strands across the sharp edge of the hole, producing a uniformly trimmed shield.

Abstract: A method of reducing entanglement of wires includes receiving from a wire feed system of a wire processing machine a first wire on a tray surface providing a wire-to-surface coefficient of friction between the tray surface and the first wire. In addition, the method includes receiving from the wire feed system a second wire at least partially on top of the first wire, the wire-to-surface coefficient of friction being higher than a wire-to-wire coefficient of friction between the first wire and the second wire. The method also includes moving the second wire relative to the first wire, and reducing movement of at least a portion of the first wire relative to the tray surface during movement of the second wire relative to the first wire due to the wire-to-surface coefficient of friction being higher than the wire-to-wire coefficient of friction.

Abstract: An apparatus is provided relating to the insertion of one or more wires into a cavity of a fixture of a structure or component. The wire insertion apparatus includes a grommet, a gripper adapted to interface with the grommet, and at least a first vibrating element. The first vibrating element is connected to and vibrates one or more of the apparatus, the grommet, the gripper, the wire, and/or a component of the apparatus. Vibration, induced in any direction, enables the cavities to shift position during insertion relative to the contact, thus increasing the tolerance of the cavity, reducing the failure rate of wire insertion, and reducing total production time. The vibration breaks the static friction of the contact in the grommet or dielectric opening, creates the positive locating required to insert the contact in the grommet and/or dielectric, and/or pivots the contact.

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: 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.