Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J11/00—Manipulators not otherwise provided for
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J13/00—Controls for manipulators
  • B25J13/08—Controls for manipulators by means of sensing devices, e.g. viewing or touching devices
  • B25J13/081—Touching devices, e.g. pressure-sensitive
  • B25J13/084—Tactile sensors
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J13/00—Controls for manipulators
  • B25J13/08—Controls for manipulators by means of sensing devices, e.g. viewing or touching devices
  • B25J13/085—Force or torque sensors
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J15/00—Gripping heads and other end effectors
  • B25J15/0052—Gripping heads and other end effectors multiple gripper units or multiple end effectors
  • B25J15/0066—Gripping heads and other end effectors multiple gripper units or multiple end effectors with different types of end effectors, e.g. gripper and welding gun
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J17/00—Joints
  • B25J17/02—Wrist joints
  • B25J17/0208—Compliance devices
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J19/00—Accessories fitted to manipulators, e.g. for monitoring, for viewing; Safety devices combined with or specially adapted for use in connection with manipulators
  • B25J19/02—Sensing devices
  • B25J19/021—Optical sensing devices
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
  • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
  • B25J9/00—Program-controlled manipulators
  • B25J9/16—Program controls
  • B25J9/1679—Program controls characterised by the tasks executed
  • B25J9/1687—Assembly, peg and hole, palletising, straight line, weaving pattern movement
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
  • H01B13/012—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses
  • H01B13/01236—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing wire harnesses the wires being disposed by machine
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
  • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
  • H01R43/28—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for wire processing before connecting to contact members, not provided for in groups H01R43/02 - H01R43/26
• • G—PHYSICS
  • G05—CONTROLLING; REGULATING
  • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
  • G05B2219/00—Program-control systems
  • G05B2219/30—Nc systems
  • G05B2219/45—Nc applications
  • G05B2219/45097—Cable harnessing robot

Definitions

• the present invention in some embodiments thereof, relates to systems and methods for automatic electrical wiring and, more particularly, but not exclusively, to systems and methods for automatic insertion of electrical wires into electrical terminal connectors.
• Preparation and wiring of electrical panels comprises a complicated process of wire architecture design and hard wiring labor.
• the present invention discloses systems and methods for automatic insertion of electrical wires into electrical terminal connectors, which can also be optionally used, for example, for systems and methods for automatic electrical wiring of panels.
• Example 1 An automatic system for electrical wiring comprising: a. at least one wiring arm module comprising a wiring-end effector at its distal end for manipulating wires to be inserted in a hole of an electrical connector; b. circuitry, which coordinates the operation of said at least one wiring arm module and said wiring-end effector using at least one parameter related to said electrical connector; c. one or more sensors configured to detect a parameter related to a wire while being inserting in said hole of said electrical connector by said wiring-end effector.
• Example 2. The automatic system for electrical wiring according to example 1, wherein said at least one parameter is one or more of a state of said wire, a deformation of said wire, a position of said wire, a force applied on said wire, a torque applied on said wire.
• Example 3 The automatic system for electrical wiring according to example 1, wherein said wiring-end effector comprises a wire holding element.
• Example 4 The automatic system for electrical wiring according to example 3, wherein said wire holding element comprises a wire pinching element comprising two extensions.
• Example 5 The automatic system for electrical wiring according to example 4, wherein said two extensions are two elongated extensions.
• Example 6 The automatic system for electrical wiring according to example 4, wherein said two extensions are brought together by an electrical mechanism.
• Example 7 The automatic system for electrical wiring according to example 4, wherein said two extensions are brought together by a pneumatic mechanism.
• Example 8 The automatic system for electrical wiring according to example 3, wherein said wire holding element comprises a motor for movement along an entry axis of an electrical terminal connector in said object.
• Example 9 The automatic system for electrical wiring according to example 3, wherein said wiring-end effector comprises one or more sensors for monitoring forces applied on said wire holding element.
• Example 10 The automatic system for electrical wiring according to example 1, wherein said wiring-end effector comprises a wire locking element.
• Example 11 The automatic system for electrical wiring according to example 10, wherein said wire locking element comprises an electrical terminal connector locking mechanism actuator.
• Example 12 The automatic system for electrical wiring according to example 11, wherein said wire locking element comprises one or more motors to move said actuator in one or more directions for interacting with a locking mechanism in an electrical terminal connector.
• Example 13 The automatic system for electrical wiring according to example 10, wherein said wire locking element comprises one or more torque sensors for monitoring the locking actuation of said wire locking element on a locking mechanism in an electrical terminal connector.
• Example 14 The automatic system for electrical wiring according to example 13, wherein said wire locking element is configured to actuate said a locking mechanism in said electrical terminal connector according to predetermined torqueing parameters monitored by said torque sensors.
• Example 15 The automatic system for electrical wiring according to example 1, wherein said circuitry receives said at least one parameter related to said electrical connector from one or more of an electronic device, a computer, a tablet, a cellphone and a server.
• Example 16 The automatic system for electrical wiring according to example 1, further comprising a monitoring system.
• Example 17 The automatic system for electrical wiring according to example 16, wherein said monitoring system comprises one or more cameras.
• Example 18 The automatic system for electrical wiring according to example 16, wherein said monitoring system comprises one or more sensors.
• Example 19 The automatic system for electrical wiring according to example 16, wherein said monitoring system comprises one or more force sensors.
• Example 20 The automatic system for electrical wiring according to example 16, wherein said monitoring system comprises one or more torque sensors.
• Example 21 The automatic system for electrical wiring according to example 16, wherein said monitoring system comprises one or more current sensors.
• Example 22 The automatic system for electrical wiring according to example 1, further comprising said object in need of electrical wiring.
• Example 23 The automatic system for electrical wiring according to example 1, wherein said at least one wiring arm module is configured to approach said object in need of electrical wiring from the side.
• Example 24 The automatic system for electrical wiring according to example 1, wherein said at least one wiring arm module is configured to approach said object in need of electrical wiring along the terminal wire port angle.
• Example 25 A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.
• Example 26 The wiring end effector according to example 25, wherein said two extensions are two elongated extensions.
• Example 27 The wiring end effector according to example 25, wherein said at least one sensor is located in said wire holding element.
• Example 28 The wiring end effector according to example 25, wherein said at least one sensor is located in said two extensions.
• Example 30 A method of automatic connecting at least one wire to at least one connector, comprising: a. automatically grabbing a distal end of a wire by means of a wire holder; b. automatically moving said wire holder to bring said distal end of said wire close to said connector; c. automatically inserting said distal end of said wire in said connector; d. automatically assessing if said at least one wire is correctly connected to said at least one connector; wherein said method further comprises sensing at least one parameter of said wire in relation to said connector during said automatically inserting and said automatically assessing.
• Example 31 The method according to example 30, wherein said at least one parameter is one or more of a state of said wire, a deformation of said wire, a position of said wire, a force applied on said wire, a torque applied on said wire.
• Example 32 The method according to example 30, wherein said inserting is performed by moving said wire holder.
• Example 33 The method according to example 30, wherein said inserting is performed by moving said connector.
• Example 34 The method according to example 30, wherein said inserting is performed by moving a robotic arm on which said wire holder is mounted.
• Example 35 The method according to example 30, wherein said sensing comprises sensing a force applied to said at least one wire when coming in contact with said at least one connector.
• Example 36 The method according to example 30, further comprising automatically locking said at least one wire in said at least one connector by actuating at least one locking mechanism.
• Example 37 The method according to example 30, wherein said automatically assessing comprises pulling back said at least one wire from said at least one connector.
• Example 38 The method according to example 37, wherein said assessing comprises sensing if said at least one wire resists said pulling back.
• Example 39 A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. a locking device comprising an electrical terminal connector locking mechanism actuator.
• Example 40 The wiring end effector according to example 39, further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.
• Example 41 A wiring end effector, comprising: a. a wire holding element comprising two extensions; b. a locking device comprising an electrical terminal connector locking mechanism actuator; c. a wire feeder configured to feed at least one wire to said wire holding element.
• Example 42 The wiring end effector according to example 41 , further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.
• Example 43 A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. a camera configured to monitor the actions of said wire holding element.
• Example 44 The wiring end effector according to example 43, further comprising a locking device comprising an electrical terminal connector locking mechanism actuator.
• Example 45 The wiring end effector according to example 43, further comprising a wire feeder configured to feed at least one wire to said wire holding element.
• Example 46 The wiring end effector according to example 43, further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.
• Example 47 A wiring end effector, comprising: a. a wire holding element comprising two extensions; and b. a wire cutter configured to cut a distal of a wire being held by said wire holding element.
• Example 48 The wiring end effector according to example 47, further comprising a camera configured to monitor the actions of said wire holding element.
• Example 49 The wiring end effector according to example 47, further comprising a locking device comprising an electrical terminal connector locking mechanism actuator.
• Example 50 The wiring end effector according to example 47, further comprising a wire feeder configured to feed at least one wire to said wire holding element.
• Example 51 The wiring end effector according to example 47, further comprising at least one sensor configured to monitor forces applied to at least one wire being held by said wire holding element.
• Example 52 A method of automatic wiring a lightning unit by connecting at least one wire to at least one connector, comprising: a. automatically grabbing a distal end of a wire by means of a wire holder; b. automatically moving said wire holder to bring said distal end of said wire close to said connector; c. automatically inserting said distal end of said wire in said connector; d. automatically assessing if said at least one wire is correctly connected to said at least one connector; wherein said method further comprises sensing at least one parameter of said wire in relation to said connector during said automatically inserting and said automatically assessing.
• Example 53 The method according to example 52, wherein said at least one parameter is one or more of a state of said wire, a deformation of said wire, a position of said wire, a force applied on said wire, a torque applied on said wire.
• Example 54 The method according to example 52, wherein said inserting is performed by moving said wire holder.
• Example 55 The method according to example 52, wherein said inserting is performed by moving said connector.
• Example 56 The method according to example 52, wherein said inserting is performed by moving a robotic arm on which said wire holder is mounted.
• Example 57 The method according to example 52, wherein said sensing comprises sensing a force applied to said at least one wire when coming in contact with said at least one connector.
• Example 58 The method according to example 52, further comprising automatically locking said at least one wire in said at least one connector by actuating at least one locking mechanism.
• Example 59 The method according to example 52, wherein said automatically assessing comprises pulling back said at least one wire from said at least one connector.
• Example 60 The method according to example 59, wherein said assessing comprises sensing if said at least one wire resists said pulling back.
• some embodiments of the present invention may be embodied as a system, method or computer program product. Accordingly, some embodiments of the present invention may take the form of an entirely hardware embodiment, an entirely software embodiment (including firmware, resident software, micro-code, etc.) or an embodiment combining software and hardware aspects that may all generally be referred to herein as a “circuit,” “module” or “system.” Furthermore, some embodiments of the present invention may take the form of a computer program product embodied in one or more computer readable medium(s) having computer readable program code embodied thereon. Implementation of the method and/or system of some embodiments of the invention can involve performing and/or completing selected tasks manually, automatically, or a combination thereof. Moreover, according to actual instrumentation and equipment of some embodiments of the method and/or system of the invention, several selected tasks could be implemented by hardware, by software or by firmware and/or by a combination thereof, e.g., using an operating system.
• a data processor such as a computing platform for executing a plurality of instructions.
• the data processor includes a volatile memory for storing instructions and/or data and/or a non-volatile storage, for example, a magnetic hard-disk and/or removable media, for storing instructions and/or data.
• a network connection is provided as well.
• a display and/or a user input device such as a keyboard or mouse are optionally provided as well.
• the computer readable medium may be a computer readable signal medium or a computer readable storage medium.
• a computer readable storage medium may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing.
• a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.
• a computer readable signal medium may include a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electromagnetic, optical, or any suitable combination thereof.
• a computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device.
• Program code embodied on a computer readable medium and/or data used thereby may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.
• Computer program code for carrying out operations for some embodiments of the present invention may be written in any combination of one or more programming languages, including an object oriented programming language such as Java, Smalltalk, C++ or the like and conventional procedural programming languages, such as the "C" programming language or similar programming languages.
• the program code may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer or entirely on the remote computer or server.
• the remote computer may be connected to the user's computer through any type of network, including a local area network (FAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider).
• FAN local area network
• WAN wide area network
• Internet Service Provider for example, AT&T, MCI, Sprint, EarthLink, MSN, GTE, etc.
• These computer program instructions may also be stored in a computer readable medium that can direct a computer, other programmable data processing apparatus, or other devices to function in a particular manner, such that the instructions stored in the computer readable medium produce an article of manufacture including instructions which implement the function/act specified in the flowchart and/or block diagram block or blocks.
• the computer program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other devices to cause a series of operational steps to be performed on the computer, other programmable apparatus or other devices to produce a computer implemented process such that the instructions which execute on the computer or other programmable apparatus provide processes for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks.
• Some of the methods described herein are generally designed only for use by a computer, and may not be feasible or practical for performing purely manually, by a human expert.
• a human expert who wanted to manually perform similar tasks such as the insertion of wires into sockets/terminals/connectors, might be expected to use completely different methods, e.g., making use of expert knowledge and/or the pattern recognition capabilities of the human brain, which would be vastly more efficient than manually going through the steps of the methods described herein.
• Figures 1 A-E are schematic representations of an exemplary method of inserting a wire into an electrical terminal connector when performed by a human;
• Figure 2 is a schematic representation of an exemplary wiring arm module, according to some embodiments of the invention.
• Figure 3A is a schematic representation of exemplary wiring-end effector module, according to some embodiments of the invention.
• Figure 3B is a schematic representation of an exemplary wire holding element of an exemplary wiring-end effector module, according to some embodiments of the invention.
• Figure 3C is a schematic representation of the sensors located on the extensions, according to some embodiments of the invention.
• Figures 3D-E are schematic representations of exemplary gimbal blocks to which the extensions are connected, according to some embodiments of the invention.
• Figure 3F is a schematic representation of an exemplary wire locking element, according to some embodiments of the invention.
• Figure 3G are schematic representations of exemplary possible interactions of wiring-end effector modules with different types of electrical terminal connector locking mechanisms, according to some embodiments of the invention.
• Figures 3H-I are schematic representations of exemplary wire end-effector of the automated electrical wiring system, according to some embodiments of the invention.
• Figure 3J is a schematic close view of the gripper and the extensions, according to some embodiments of the invention.
• Figure 3K is a schematic representation of an exemplary wiring-end effector module comprising a camera, according to some embodiments of the invention.
• Figures 4A-B are schematic representations of exemplary ferrules, according to some embodiments of the invention.
• Figures 5A-C are flowcharts of an exemplary method of wiring by an exemplary wiringend effector module, according to some embodiments of the invention.
• Figure 6 is a schematic representation of an automated electrical wiring for lightning units, according to some embodiments of the invention.
• Figure 7 is a graph describing the exemplary phases of the insertion of a wire into an electrical terminal connector as identified by the sensors in the gripper, according to some embodiments of the invention.
• Figures 8A-C are three different examples of sensed forces by the gripper in three different scenarios, according to some embodiments of the invention.
• Figure 9 illustrates a plurality of test experiments for the characterization of exemplary scenarios, according to some embodiments of the invention.
• the present invention in some embodiments thereof, relates to systems and methods for automatic electrical wiring and, more particularly, but not exclusively, to systems and methods for automatic insertion of electrical wires into electrical terminal connectors.
• An aspect of some embodiments of the invention relates to automated wiring of an electrical panel and performing the connection of the wires to the connectors by automated machines.
• the automated wiring machines comprise a plurality of sensors for tactile feedback, which potentially increases the insertion process robustness of wires in their correct location and potentially reduces the time of validation processes.
• an aspect of some embodiments of the invention relates to insertion of wires into electrical connectors by robotic manipulators.
• the robotic manipulators comprise smart holders comprising a plurality of sensors.
• the holders comprise are finger-like holders.
• insertion of wires comprises manipulating a wire and receiving feedback from a plurality of sensors about the status of the wire, optionally also in relation to the electrical connector.
• the inventors would like to convey one of the many possible challenges in the robotic automation performance in general, and specifically, in the robotic automation for electrical wiring manipulation.
• the inventors have found that in order to perform correct manipulation of electrical wires into an electrical terminal connector a certain level of sensibility is required. For example, a technician or user, utilizing his somatosensory system (for example: touch), holds the wire with one hand and inserts it in the electrical terminal connector, while sometimes the other hand performs the locking actions to lock the wire in the electrical terminal connector.
• somatosensory system for example: touch
• the user must use just the necessary force when inserting the wire into the electrical terminal connector for, on one side, inserting and keeping the wire in the electrical terminal connector while it is being locked and, on the other side, avoiding deformation of the wire due to the application of excessive force. It is also common in the art for the user to “feel” or assess that the wire is secured in location by slightingly pulling it after the locking action has been performed. In the following paragraphs exemplary actions performed by a human will be described to allow a person having skills in the art to understand the challenges when translating apparent easy tasks performed by humans into robotics.
• FIG. 1A-E showing schematic representations of an exemplary method of inserting a wire into an electrical terminal connector when performed by a human.
• a human uses tactile feedback to secure a cable into a connector/device
• a typical cycle of actions includes (see Figures 1A-1E):
• these actions are performed using capabilities that are referred herein as Grip and Slip capabilities.
• the wiring system optionally comprising arm modules and wiring-end effector modules comprise a plurality of sensors (see below) configured to monitor the interactions of the modules with the wires and/or the electrical terminal connectors.
• the arm modules and the wiring-end effector modules are actuated using a combination of motors, sensors and software that enable compliance based mechanisms with antagonistic elastic actuation as opposed to rigid-linkage based robot grippers. In some embodiments, this allows a higher variability in gripping force control.
• the software comprises information regarding payload weights/stiffness and structure and program that enhances the correct function (grasp planning) of the grippers without overshoot/ringing.
• parts of the arms and or grippers may be automatically changed for specific tasks for example to hold different tools such as tweezers or cutters.
• the robotic parts of the wiring system comprise fine motor skills.
• the automated wiring system (in general) and the wiring arm(s) modules of the present invention comprises, in addition to the one or more sensors dedicated to the manipulation of the wire, a plurality of articulations that confers a plurality of degrees of freedom of movement to the system.
• the automated wiring system comprises a wiring arm module 200 comprises a plurality of articulations 202, 204, 206.
• the articulations confers a plurality of degrees of freedom of movement.
• articulations 202, 204, 206 can potentially confer between 4 to 8 degrees of freedom of movement as shown by the arrows.
• the articulations disclosed herein are just examples to allow a person having skills in the art to understand the invention, and that greater or fewer articulations can be used.
• the system can be Cartesian with rotary end effector or fully articulated.
• the wiring arm modules 200 comprise a wiring-end effector module 300, which comprise a plurality of motors and sensors that perform forces and measurements of the axial and radial forces, similarly to the actions performed by a human, in order to provide a system with high levels of dexterity and sensibility capable to perform wiring actions.
• the wiring-end effector module 300 includes one or more optical sensors, for example, one or more cameras and/or lasers scanners.
• the wiring-end effector module 300 includes multiple 2D and/or 3D cameras.
• the wiring arm module is optional, meaning a more simplistic holder of the wiring-end effector module 300 can be used.
• examples of an automated wiring system comprising dedicated wiring arm modules 200 will be used to explain the invention. It should be understood that other types of platforms capable of actuating the wiringend effector module 300 can be used and are also included in the scope of the invention.
• a typical arm has a payload of about lOKg and accuracy of better than 0.1mm.
• a Cartesian gantry style arm or dual arms are used for main movement (XYZ) while the fine local movement is done by 2 or 3 rotating axes along with an end effector.
• the wiring-end effector module 300 comprises one or more of the following parts: a wire holding element 302 and a wire locking element 304.
• Figure 3B showing a schematic representation of the parts of the wire holding element 302, according to some embodiments of the invention.
• the wire holding element 302 comprises one or more of a base 306 comprising wire pinching element 308.
• the wire pinching element 308 comprises two extensions 310a-b, optionally elongated finger-like extensions, which are brought together, for example, by an electrical mechanism 312 and/or by a pneumatic mechanism.
• the wire pinching element 308 comprises a gimbal block 370 to which the two extensions 310a-b are connected (see below further explanations regarding gimbal block 370).
• the base 306 comprises one or more motors 314/328 that allow a horizontal movement of the wire holding element 302, in the direction as schematically shown by arrow 316.
• the wiring arm module provides the motion along schematic arrow 316.
• the horizontal movement shown by arrow 316 is the direction along the axis of the wire towards the electrical terminal connector.
• the motion is in line with the wire terminal port that may be, for example, at an angle of 30, 45, 90 degrees (or any angle in between) from the plane of the panel.
• one or more of the extensions 310a-b comprise one or more sensors 318 configured to monitor the force applied by the elongated extensions 310a-b on the wire 320.
• sensors are embedded in the finger or the body of the end-effector.
• those sensors allow, for example, the measurements of the axial and radial forces, similarly to the actions performed by a human, which provide a system with high levels of sensibility capable to perform wiring actions, as explained above.
• sensors are based for example, on strain gauges, load-cells and/or others.
• mechanism that can sense forces or moments are located on the part where the extensions are connected to the device, for example the gimbal block (see 370 in Figure 3B), as shown and explained below for Figures 3D-E.
• the extensions 310a-b can be replaced, automatically and/or manually, to accommodate a different wire gauge.
• electrical mechanism 312 includes an anti-collision mechanism that protects the fingers.
• electrical mechanism 312 includes sensors that can measure moments that are applied by the elongated extensions 310a-b during insertion, for example moments at a value of from about 0.01NM to about 0.1NM.
• the gimbal block 370 comprises a plurality of parts that allow the monitoring of forces applied on the extensions 310a-b.
• the plurality of parts are one or more gimbals mounted on top of each other but having different axis of movement.
• two axis of movement will be described. It should be understood that more gimbals can be use, thereby providing more than two axis of movement that can be monitored. These are also part of the scope of the invention.
• the gimbal block 370 comprises a top block 372, which connects the gimbal block 370 to the rest of the device.
• a top connector 374 which is connected to the top block 372 by means, for example, of screws 376.
• one or more damping springs 396 in communication with one or more Button Axis Load Cells 378 are housed between the top block 372 and the top connector 374.
• calibration of the Load Cells is performed by actuating the Damping Force Calibrating set screw 380.
• below the top connector 374 there is a center block 382.
• first gimbal axis 384 which confers the axis of movement perpendicular to the pin of the first gimbal axis 384 in the horizontal direction (see below explanations about the movement of the gimbal block).
• second gimbal axis 386 shown in an inserted position.
• the second gimbal axis 386 is perpendicular to the first gimbal axis 384.
• the second gimbal axis 386 confers the axis of movement perpendicular to the pin of the second gimbal axis 386 in the horizontal direction (see below explanations about the movement of the gimbal block).
• a bottom connector 388 which is connected on the top to the center block 382 and on the bottom to a bottom block 390.
• another set of one or more damping springs in relation/interface with another set of one or more Button Axis Load Cells are housed between the bottom connector 388 and the bottom block 390.
• the extensions 310a-b are connected to the bottom block 390.
• the device comprises one gimbal block 370 to which both extensions 310a-b are connected. In some embodiments, the device comprises two gimbal blocks 370, one gimbal block 370 for each extension, as shown for example in Figure 3E.
• the gimbal block 370 comprises a first gimbal axis 384, which provides the gimbal block 370 movement in a first axis, and a second gimbal axis 386, which provides the gimbal block 370 movement in a second axis.
• a side view of the gimbal block 370 is shown, showing the movement (arrow 392) enabled by the first gimbal axis 384.
• FIG. 3E a front view of the gimbal block 370 is shown, showing the movement (arrow 394) enabled by the second gimbal axis 386.
• the first gimbal axis 384 and the second gimbal axis 386 provide the gimbal block 370 with dual rotational axes at different locations.
• these rotational axes are used with the single axis load cell to measure moments and force applied on the extensions.
• the two extensions are each separately connected to a gimbal block 370, therefore allowing measurement of different forces on each extension.
• the system may halt the insertion operation of the wire and/or take corrective actions (moving the device).
• the wire locking element is configured to interact with the wire locking mechanism of the electrical terminal connector after the wire is inserted.
• different electrical terminal connectors comprising different wire locking mechanisms are used, for example: screw terminal, push button and/or push-in.
• screw terminal or screw type terminal connector secure the wire against the conductor in the electrical terminal connector by tightening a screw which closes a clamp.
• push button terminal connector secure the wire against the conductor by a spring clamp that is opened by pressing a button. In some embodiments, releasing the button clamps the spring onto the wire. In some embodiments, similar to the push button with a spring clamp, a push-in terminal connectors allows the wire to be pressed directly into the housing without the use of a push button to open the spring.
• the wire locking element 304 will comprise a dedicated actuator 322. For example, in Figure 3F, the wire locking element 304 comprises a flat head screwdriver 322 which is used to close screw type terminal connectors.
• the head of the actuator and/or the drill bit 322 can be replaced manually or optionally automatically (for example, by moving the device towards a replacement rack where the vertical movement 330 is used to replace the head of the actuator 322).
• Figure 3G showing schematically representations of a plurality of possible interactions of wiring-end effector modules 300 with different types of electrical terminal connector locking mechanisms.
• the wire locking element 304 comprises a motor 324 configured to actuate the dedicated actuator 322, for example by rotating the head of the actuator 322.
• the motor 324 and the dedicated actuator 322 are held by a base 326, which is further connected to a second motor 314/328 that performs a vertical movement, as schematically shown by arrow 330, necessary for the insertion of the dedicated actuator 322 into the electrical terminal connector locking mechanism.
• a plurality of motors are used to provide a plurality of movement directions to the wire locking element 304.
• the wire locking element 304 is configured to move up and down, to the sides and forwards-backwards.
• a potential advantage of providing such freedom of movement to the locking element 304 is that it allows the device to interact with a plurality of electrical terminal connectors, each having a different location for the access to the wire locking mechanism.
• the wire locking element 304 comprises a torque sensor configured to monitor the torqueing forces applied by the actuator on the locking mechanism of the electrical terminal connector.
• the system comprises a database where specific torque forces related to specific locking mechanisms of electrical terminal connectors are saved.
• the system comprises instructions to actuate the actuator according to specific parameters which specifically match the torqueing requirements of specific locking mechanism of specific electrical terminal connectors.
• the wire end-effector 300 comprises a mechanical wire feeder 332 comprising a dedicated motor 334 configured to feed the necessary wire 320 into the gripper 308.
• the gripper 308 comprises two (optionally finger-like) extensions 310a-b configured to pinch and hold the wire 320.
• each extension is connected to a force providing mechanism 336a-b, configured to perform the movement of the two extensions 310a-b that actuates the pinching/holding action.
• a dedicated motor 314/328 is connected to the force providing mechanism 336a-b.
• the wire end-effector 300 comprises an end-wire cutter 338 configured to take out the isolation around the wire and expose the core of the wire.
• the wire end-effector 300 optionally comprises a vacuum system (not shown) configured to pick up the waste from the end-wire cutter 338 and transport it into a waste container 340.
• the gripper 308 comprises one or more sensors 318 on the extensions 310a- b configured to monitor the force applied by the gripper 308.
• the sensors are alternatively or additionally in the gimbal block(s) 370 that are holding the extensions.
• the gripper 308 applies and monitors forces in three main directions (marked as F , F and FM,)-
• the forces are used for the insertion of the wire 320 into the wire terminal 344, as schematically shown on the left side of Figure 3h.
• the forces F , FM and F ,) are from about 5N to about 15N, optionally from about 7N to about 20N, optionally from about 8N to about 25N, for example about 8N, about 10N, about 12N.
• the resolution of any of the above forces are of about IN.
• a wiring arm module 200 comprise a wiring-end effector modules 300, optionally comprises a camera 346, as shown for example in Figure 3K. It should be understood that in any of the embodiments of the wiring-end effector modules 200, a camera is optionally added. Exemplary use of wires having end terminal ferrules
• the wires used in the automatic wiring system are wires that comprise a built-in ferrule at the distal end.
• Ferrules are a ring or cap 402, optionally having a metal distal end 404, used to enclose the distal end of the exposed wire in order to facilitate the handling and connection of the distal end of the wire into the electrical terminal connector.
• the ferrule is stiff. In some embodiments, the ferrule is stiffer than the wire itself. In some embodiments, the ferrule is between about 2 and about 10 times stiffer than the wire.
• ferrules can have different dimensions, as shown for example in Figure 4A. In some embodiments, the ferrules can have a different form of the metal part 404 at the distal end, as shown for example in Figure 4B.
• the wiring-end effector module 300 pinches the cap 402 instead of directly pinching the wire.
• a potential advantage of pinching the cap 402 is that it eases the manipulation of the wire during the insertion into the electrical terminal connector. Since the wire is pliant, it can happen that the wire bends during the insertion causing a deviation in the directionality of the head of the wire that needs to be inserted in the electrical terminal connector.
• ferrules are configured to be completely inserted into the electrical terminal connectors, meaning that the cap 402 needs to be completely inserted inside the electrical terminal connector in order to be correctly connected.
• the method of insertion of the wire into the electrical terminal connector comprises additional steps, as will be further disclosed below.
• the additional actions needed to be performed during the insertion of a wire including a ferrule include one or more of: the partial insertion of the ferrule into the electrical terminal connector, release or partial release of the ferrule, moving backwards of the device, re-pinching the wire at a distal location in the wire in relation to the ferrule, finishing the insertion of the wire and ferrule in the electrical terminal connector.
• the system before the release of the ferrule, the system optionally partially closes the locking mechanism of the electrical terminal connector to partially hold the ferrule in place and potentially avoid the ferrule from exiting the electrical terminal connector.
• the wiring-end effector module 300 comprises an additional element configured to hold the wire in place while the extensions are moved to a more distal position on the wire.
• the additional element can be a third extension configured to be extended when needed and to hold in place the wire.
• the elongated extensions grab the wire by applying radial force on the wires 502.
• the force applied on the wire is from about 5N to about 15N, optionally from about 7N to about 20N, optionally from about 8N to about 25N, for example about 8N, about 10N, about 12N.
• the resolution of any of the above forces are of about IN.
• the effector module brings the wire close to the connector by applying axial force 504.
• the force applied on the wire is from about 5N to about 15N, optionally from about 7N to about 20N, optionally from about 8N to about 25N, for example about 8N, about 10N, about 12N.
• the resolution of any of the above forces are of about IN.
• the wire is then inserted in the hole of the connector 506.
• the system then senses the resistance on the wire by the fact the wire reached the end of the hole in the connector 508.
• the system then secures the wire in the connector (see above ways to secure the wire in the connector) 510.
• the system then pulls back wire by lightly applying contrary directional axial force, while sensing resistance from gabbing sensors, to evaluate firm connection of wire in the connector 512. In some embodiments, the system then slightly reduces the radial force on the wire while keeping holding the wire 514. In some embodiments, when the insertion of the wire was the last wire to be connected in the electrical panel, then the method ends. In some embodiments, the system then allows the wire (that is still held by the elongated extensions) to slip in the elongated extensions, without releasing the wire, while moving the mechanical arm away from the connector 516. In some embodiments, the system then continues with the wiring process, as explained therein elsewhere 518.
• the extensions grab the wire by applying radial force on the ferrule 520.
• the force applied on the ferrule is from about 3N to about 110N, optionally from about 7N to about 20N, optionally from about 8N to about 25N, for example about 8N, about 10N, about 12N.
• the resolution of any of the above forces are of about 0.5N.
• the effector module brings the ferrule close to the connector by applying axial force 522.
• the force applied on the wire is from about 3N to about 15N, optionally from about 7N to about 20N, optionally from about 8N to about 25N, for example about 8N, about ION, about 12N. In some embodiments, the resolution of any of the above forces are of about 0.25N.
• the ferrule is then partially inserted in the hole of the connector 524. In some embodiments, optionally, the system partially closes the locking mechanism in the electrical terminal connector to hold the ferrule in place 526. In some embodiments, the wire with the ferrule are held in place 528. In some embodiments, this is performed by one or more additional elements as disclosed above. In some embodiments, the extensions are actuated to release the ferrule 530.
• the device is moved backwards in line with the wire 532.
• the extensions re-grab the wire on the wire itself 534.
• the system opens the previously partially closed locking mechanism of the electrical terminal connector 536.
• the system then applies axial force to completely inserting the ferrule into the electrical terminal connector 538.
• Flowchart continues in Figure 5C following the letter A.
• the system then senses the resistance on the wire by the fact the wire reached the end of the hole in the connector 540.
• the system secures the wire in the connector (see above ways to secure the wire in the connector) 542.
• the system then pulls back wire by lightly applying contrary directional axial force, while sensing resistance from gabbing sensors, to evaluate firm connection of wire in the connector 544. In some embodiments, the system then slightly reduces the radial force on the wire while keeping holding the wire 546. In some embodiments, when the insertion of the wire was the last wire to be connected in the electrical panel, then the method ends. In some embodiments, the system then allows the wire (that is still held by the elongated extensions) to slip in the elongated extensions, without releasing the wire, while moving the mechanical arm away from the connector 548. In some embodiments, the system then continues with the wiring process, as explained therein elsewhere 550.
• the parameters sensed by the one or more sensors are saved in a data base.
• the automated electrical wiring system is used for the wiring of lighting units.
• the automated electrical wiring for lightning units 600 comprises a base 602 on which the different parts of the automated electrical wiring for lightning units 600 are mounted.
• the automated electrical wiring for lightning units 600 comprises at least one robotic arm 604 comprising a wire end-effector 606.
• the automated electrical wiring for lightning units 600 optionally comprises a depth camera 608 configured to monitor the wiring actions of the system.
• a depth camera 608 configured to monitor the wiring actions of the system.
• an exemplary lighting panel 610 in the location where the wiring process is performed.
• a camera 612 is used to monitor the wiring process.
• a controller 614 and a user interface 616 for controlling the system.
• the system is configured to identify the different phases of the insertion of the wire into the electrical terminal connector, as further disclosed above.
• the graph in Figure 7 shows the force sensed by the sensors on the fingerlike extensions 310a-b in the gripper 308 in relation to the held wire.
• the phases are:
• Phase A movement forward towards the electrical terminal connector.
• the wire is held by the gripper 308 and the gripper 308 is moving forward towards the electrical terminal connector.
• the sensed force is the same as the wire has not met any obstruction.
• the wire meets the electrical terminal connector, and the sensors begin to sense an increase in the sensed force.
• the peak may depend and optionally set based on type of wire and/or the type of electrical terminal connector.
• the relation between the type of wire, the type of connector and the “sensed” forces is learned by the system and stored in a dedicated database.
• Phase B movement backwards from the electrical terminal connector.
• the gripper 308 will begin moving backwards while still holding the wire but without actually pulling the wire with it.
• the sensed forces decrease drastically, as the gripper loosens the grip.
• Phase C movement backwards from the electrical terminal connector while pulling the wire.
• the gripper gently holds the wire while continuing moving backwards from the electrical terminal connector.
• two possible things can happen: 1. the wire is correctly connected and will not move causing the gripper to slip over the connected wire; or 2. the wire is not connected correctly and will be pulled out the electrical terminal connector.
• the values are learned and/or adjusted after each attempt.
• the system comprises a database in which the different combinations of different types of electrical terminal connectors and different types of wires are kept, and according to the input provided by the user, the system will actuate the gripper accordingly.
• Figure 8A shows an example of what the sensors sense during the movement backwards of the gripper and the wire did not connect at all with the electrical terminal connector. In this case, there is no increase of the sensed force since the wire does not resist the pulling of the gripper.
• Figure 8B shows an example of what the sensors sense during the movement backwards of the gripper and the wire did not connect correctly with the electrical terminal connector.
• the gripper begins to move backwards until the wire resists the pulling, which is translated to an increase in the sensed force.
• the wire is not properly connected, it will detach from the electrical terminal connector, which is evidenced by the sudden decrease in the sensed force, and then return to the same levels as in the beginning.
• Figure 8C shows an example of what the sensors sense during the movement backwards of the gripper and the wire did connect correctly with the electrical terminal connector.
• the gripper begins to move backwards until the wire resists the pulling, which is translated to an increase in the sensed force.
• the gripper will begin slipping over the wire, which is evidenced by the reduction of the sensed force on the gripper at the end of the graph.
• Test 2 the wire disconnected from the connector during the pulling backwards of the wire.
• test 3 the wire connected perfectly to the connector, and the gripper slipped over the wire during the backwards movement.
• Test 4 the wire disconnected from the connector during the pulling backwards of the wire.
• compositions, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.
• a compound or “at least one compound” may include a plurality of compounds, including mixtures thereof.
• range format is merely for convenience and brevity and should not be construed as an inflexible limitation on the scope of the invention. Accordingly, the description of a range should be considered to have specifically disclosed all the possible subranges as well as individual numerical values within that range. For example, description of a range such as “from 1 to 6” should be considered to have specifically disclosed subranges such as “from 1 to 3”, “from 1 to 4”, “from 1 to 5”, “from 2 to 4”, “from 2 to 6”, “from 3 to 6”, etc.; as well as individual numbers within that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range.

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• Engineering & Computer Science (AREA)
• Robotics (AREA)
• Mechanical Engineering (AREA)
• Manufacturing & Machinery (AREA)
• Human Computer Interaction (AREA)
• Supply And Installment Of Electrical Components (AREA)
• Manipulator (AREA)
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• 2021
  • 2021-12-07 JP JP2023557852A patent/JP7824315B2/ja active Active
  • 2021-12-07 WO PCT/IL2021/051451 patent/WO2022123558A1/en not_active Ceased
  • 2021-12-07 WO PCT/IL2021/051456 patent/WO2022123560A1/en not_active Ceased
  • 2021-12-07 US US18/265,716 patent/US20240120697A1/en active Pending
  • 2021-12-07 EP EP21902865.1A patent/EP4255697B1/en active Active

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