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: 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 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 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 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: 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 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: 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.

Abstract: A method for assembling and installing a wire bundle assembly group (WBAG) is disclosed. The method includes placing a first grouping of components of a first WBAG on a first assembly panel of a fabrication table. The method also includes assembling the first WBAG from the first grouping of components and attaching the first WBAG to the first assembly panel. The method also includes actuating a pivot of an assembly frame supporting the first assembly panel to rotate the first assembly panel about a longitudinal axis. The method further includes placing a WBAG receiving panel of a transport tool adjacent the first WBAG and the first assembly panel. The method also includes releasing the first WBAG from the first assembly panel and dropping the WBAG onto the WBAG receiving panel. Finally, the method includes attaching the first WBAG to the WBAG receiving panel.

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: 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.