Robotic insertion for modular cable connector

Patent metadata

Field	Value
Publication number	US-2025079785-A1
Application number	US-202318460968-A
Country	US
Kind code	A1
Filing date	Sep 5, 2023
Priority date	Sep 5, 2023
Publication date	Mar 6, 2025
Grant date	—

Abstract

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

First claim

1 . A method for assembly of a modular cable connector, the method comprising:
at an end effector affixed to an articulated robot arm of a robotic insertion system, holding a cable insert module for insertion into a module slot of a module retainer; via a camera system of the robotic insertion system, capturing two or more images of the module retainer, wherein at least one of the two or more images is captured while the module retainer is illuminated by a laser alignment system of the robotic insertion system; at a controller of the robotic insertion system, performing image processing on the two or more images to identify a segmented image region corresponding to the module retainer, and to identify a virtual plane parallel to a face of the module retainer; controlling the articulated robot arm to move the cable insert module to an alignment pose determined based, at least in part, on the segmented image region and the virtual plane; controlling the articulated robot arm to move the cable insert module from the alignment pose toward an insertion pose; and upon insertion of the cable insert module into the module slot of the module retainer, releasing the cable insert module from the end effector to thereby at least partially assemble the modular cable connector.

2 . The method of claim 1 , further comprising, while controlling the articulated robot arm to move the cable insert module from the alignment pose toward the insertion pose, detecting an insertion force vector of the end effector via a force sensor of the robotic insertion system.

3 . The method of claim 2 , further comprising, based on detecting that a magnitude of the insertion force vector exceeds an insertion failure threshold, controlling the articulated robot arm to move the cable insert module toward a corrected insertion pose determined based on a direction of the insertion force vector.

4 . The method of claim 2 , further comprising, prior to releasing the cable insert module from the end effector, detecting successful insertion of the cable insert module into the module slot by applying a removal force to the cable insert module, and detecting that a magnitude of a removal force vector detected via the force sensor exceeds a retention success threshold.

5 . The method of claim 1 , further comprising, after releasing the cable insert module from the end effector, holding a second cable insert module at the end effector for insertion into a second module slot of the module retainer from a second alignment pose.

6 . The method of claim 1 , wherein a movement path of the cable insert module from the alignment pose toward the insertion pose is perpendicular to the virtual plane.

7 . The method of claim 1 , wherein a coordinate of the alignment pose relative to a vertical axis is retrieved from a look-up table, and indexed in the look-up table by a module slot identifier of the module slot of the module retainer into which the cable insert module is to be inserted.

8 . The method of claim 1 , wherein the camera system includes an RGB camera and a depth camera, and wherein the two or more images include an RGB image captured by the RGB camera, and a depth image captured by the depth camera.

9 . The method of claim 8 , wherein the segmented image region is identified based, at least in part, on detecting laser glints caused by illumination of the module retainer by the laser alignment system.

10 . The method of claim 9 , wherein said detecting the laser glints includes capturing the RGB image while the module retainer is illuminated by the laser alignment system, capturing a second RGB image after deactivation of the laser alignment system, and performing an image subtraction operation based on the RGB image and the second RGB image to generate a third RGB image.

11 . The method of claim 10 , wherein the segmented image region is detected based on pixel values of the third RGB image.

12 . The method of claim 8 , wherein the segmented image region is identified based, at least in part, on pixel values of the RGB image, and applied to the depth image based on a known alignment between the RGB camera and the depth camera, to thereby identify a set of depth values within the depth image corresponding to the module retainer.

13 . The method of claim 12 , wherein the alignment pose is determined based, at least in part, on a centroid of the set of depth values within the depth image corresponding to the module retainer.

14 . The method of claim 12 , wherein the virtual plane is identified, at least in part, by averaging a subset of the depth values within the depth image.

15 . The method of claim 1 , wherein one or more cable wires are inserted into the cable insert module prior to insertion of the cable insert module into the module retainer.

16 . A robotic insertion system, comprising:
an articulated robot arm equipped with an end effector; a laser alignment system; a camera system; and a controller configured to:
receive, via the camera system, two or more images captured of a module retainer into which a cable insert module is to be inserted into a module slot by the end effector, wherein at least one of the two or more images is captured while the module retainer is illuminated by the laser alignment system;
perform image processing on the two or more images to identify a segmented image region corresponding to the module retainer, and to identify a virtual plane parallel to a face of the module retainer;
control movements of the articulated robot arm to move the cable insert module to an alignment pose determined based, at least in part, on the segmented image region and the virtual plane;
control movements of the articulated robot arm to move the cable insert module from the alignment pose toward an insertion pose; and
upon insertion of the cable insert module into the module slot of the module retainer, control the end effector to release the cable insert module and thereby at least partially assemble a modular cable connector assembly.

17 . The robotic insertion system of claim 16 , wherein the controller is further configured to, while the cable insert module is moved from the alignment pose toward the insertion pose, detect an insertion force vector of the end effector via a force sensor of the robotic insertion system, and based on detecting that a magnitude of the insertion force vector exceeds an insertion failure threshold, move the cable insert module toward a corrected insertion pose determined based on a direction of the insertion force vector.

18 . The robotic insertion system of claim 16 , wherein the camera system includes an RGB camera and a depth camera, and wherein the two or more images include an RGB image captured by the RGB camera, and a depth image captured by the depth camera.

19 . The robotic insertion system of claim 18 , wherein the segmented image region is identified based, at least in part, on pixel values of the RGB image, and applied to the depth image based on a known alignment between the RGB camera and the depth camera, to thereby identify a set of depth values within the depth image corresponding to the module retainer.

20 . The robotic insertion system of claim 19 , wherein the alignment pose is determined based, at least in part, on a centroid of the set of depth values within the depth image corresponding to the module retainer.

21 . A computing system, comprising:
a logic subsystem; and a storage subsystem holding instructions executable by the logic subsystem t

Assignees

• Boeing Co

Inventors

• Mohlman Shawn David
• Blacken Lars Eric
• Mitchell Bradley J
• Mccaskey Jeffrey Alan
• Barletta Aldo Mario
• Stapleton Elle Suzanne
• Chan Darren
• Johnson Joel Douglas
• Lampkins Joshua
• Mcallister Wyatt

Classifications

• B25J11/00

  Manipulators not otherwise provided for · CPC title

• H01R43/205 Primary

  with a panel or printed circuit board · CPC title

• B25J9/1697 Primary

  Vision controlled systems · CPC title

• G05B2219/25321

  Connection modules by flexible printed circuit, printed cable, multiway, ribbon · CPC title

• H01R43/20 Primary

  for assembling or disassembling contact members with insulating base, case or sleeve · CPC title