Cable Assembly and Handling
Gripping, guiding and inserting flexible and dimensionally unstable materials such as cables, wires or connectors using robots
Variances, i.e. deviating geometries or positions of components or changing products on the lines, make it difficult to automate certain production steps. Therefore, cable handling and assembly has not been economically feasible with conventional automation until now. With ArtiMinds RPS software, robots can now robustly and precisely detect, grip and insert flexible workpieces such as cables, wires or connectors.
Forces and deviations can be analyzed with ArtiMinds LAR in order to optimally adapt movements and joining processes to the workpiece and given frame conditions and thus optimize production.
Automated handling, manipulation, and assembly of flexible workpieces such as cables, wires, connectors or fabrics/fabric cover pose several challenges in production. Traditional robot processes often lack the dexterity to handle these sensitive materials. Localization of the position and identification of the shape of parts are a major challenge in classic robot programming. The liability and form instability of the material results ins constantly changing dynamic of the part tolerances, shape, and localization throughout the entire handling or assembly process. But robot-based cable assembly can be programmed and implemented efficiently and robustly using ArtiMinds RPS.
You need support in automating the handling and assembly of cables? At ArtiMinds you get software & project support from a single source!
Application Example: Laser-based Cable Assembly
During harness assembly or cable harness manufacturing, flexible cables must be gripped, processed and, for example, plugged into a connector housing. Robot-based automation of this plugging process is not possible without sensors or force control and is very complex and usually not robust with conventional programming. If the cables or wires hang freely in the room, even gripping the parts in the first step is a major challenge.
The robotic approach developed by ArtiMinds for this complex cable handling application is based on a unique combination of laser line scanners, 2D camera technology and force-torque measurement, as well as interfaces and intelligent function blocks in the ArtiMinds Robot Programming Suite (RPS), which were newly developed for this purpose.
The software processes the scan result in real time and synchronizes it with the robot motion to determine the exact pickup point. It then performs a force-controlled joining operation that enables precise and safe insertion of the cables into the connector housing. During the final pull test, the robot checks whether the cable end is correctly engaged in the housing.
Application Example: Ribbon Cable Assembly
Flat ribbon cables are used for signal transmission in modules in electronics manufacturing as they save space, time and thus money. However, handling the dimensionally unstable and sensitive cables is difficult due to their low stiffness and requires a great deal of dexterity. By means of force-torque control, new areas of application can be opened up for industrial robots that cannot be implemented with realistic effort using conventional programming.
The “Spike Search” function template of ArtiMinds RPS automatically compensates for tolerances during the insertion process. That is, in order to find the correct insertion position, the robot performs a force-controlled search movement and attempts to insert the cable into the socket. As soon as a defined insertion depth is registered by the robot, it knows that it has found the socket and robustly inserts the flexible component at this position. A tensile test then ensures that the cable is correctly seated.
Further application examples:
- Plugging and unplugging cables, wires and connectors
- End-of-Line testing and tensile tests
- Covering of car seats
- Assembling cable harnesses
- Wiring of switch cabinets
- Gripping and placing cables in cable trays
- Crimping
You want more? We support you in the robot-based automation of your cable assembly
You want more? We support you in the robot-based automation of your cable assembly
You want to integrate new and flexible automation processes into your workflows and need e.g. support in automating cable handling and assembly processes? Our Automation Engineering team of engineers and robotics experts will be happy to advise you and take over tasks such as the prototyping.
ArtiMinds is a leader in the development of innovative and sophisticated robot automation solutions, whether as a partial or overall concept. Our experts will be happy to provide you with advice and support from conceptual design to implementation.
Get in touch – our specialists will provide you with comprehensive advice and develop an initial concept or carry out a feasibility study in close cooperation with you.
Industrial examples – short videos of real customer applications
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Why ArtiMinds Robotics?
The template library of ArtiMinds RPS with over 60 templates covers all conceivable movements, processes and operations. Thanks to the intelligent algorithms, force-controlled applications, for example, can be programmed without any problems. Talk to our robotics experts about your automation project, we are happy to support you!
>>BLOG ARTICLE: ArtiMinds RPS & LAR at a glance
Highlights of ArtiMinds RPS for cable handling and assembly:
- Easy integration of force-torque sensors, grippers, vision systems and laser scanners
- Force-controlled precise gripping and connecting of flexible materials such as cables, wires or connectors
- Automatic compensation of variances and shape instabilities
Choose a robot-based flexible automation solution – choose ArtiMinds. See for yourself in an online demo!
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