Wire insertion apparatus and method

• US 9,985,406 B2
• Filed: 07/23/2015
• Issued: 05/29/2018
• Est. Priority Date: 07/23/2015
• Status: Active Grant

• Current Assignee: The Boeing Co.
• Original Assignee: The Boeing Co.
• Inventors: Crocco, James R., Doyle, Stephen, Edman, Frederick C., DeStories, Jason Gerald
• Primary Examiner(s): Arbes, Carl
• Application Number:
  US14/807,247
• Publication Number:
  US 20170025808A1
• Time in Patent Office: 1,041 Days
• CPC Class Codes: H01R 43/20 for assembling or disassembling contact members with insulating base, case or sleeve

Abstract

A system for assisting in the assembly of a cable harness may include a wire insertion apparatus that includes a frame that defines a connector mounting location; a projector mount attached to the frame and positioned so that a projector held in the projector mount projects graphical information onto a connector held by the mounting location; and the projector. The system may also include a computer device in communication with the projector and comprising a module configured for: projecting, via the projector, a plurality of alignment dots onto the connector; moving the alignment dots based on a first user input; receiving a second user input that the alignment dots are aligned and, based on the second user input, determining a position and orientation of the connector; and illuminating, via the projector, one or more pin locations of the connector based on the position and orientation of the connector.

Claims

1. A system (200) for assisting the assembly of a cable harness, comprising:

a wire insertion apparatus (100, 150), the wire insertion apparatus (100, 150) comprising;

a frame (105, 155), the frame (105) defining a connector mounting location (115, 165);

a projector mount (135, 185) attached to the frame (105, 155), the projector mount (135, 185) being positioned so that a projector (140) held in the projector mount (135, 185) projects graphical information onto a connector (120) held by the mounting location (115, 165); and

the projector (140), the projector (140) being configured to project a plurality of alignment dots onto the connector (120) for use in aligning the connector (120) to establish the position and orientation of the connector, and configured to illuminate one or more pin locations of the connector (120) based on the position and orientation of the connector (120);

a computer device (202, 224) in communication with the projector and comprising;

a processor (204, 226);

a memory (206, 228); and

a module stored in the memory (206, 228), executable by the processor (204, 226) and configured to;

control the projector (140) to project the plurality of alignment dots onto the connector (120);

move the alignment dots projected onto the connector (120) based on a first user input;

receive a second user input that the alignment dots are aligned;

determine the position and orientation of the connector (120) based on coordinates of the alignment dots; and

control the projector (140) to illuminate the one or more pin locations of the connector (120) based on the position and orientation of the connector (120).

2. The system (200) according to claim 1, wherein the wire insertion apparatus (100, 150) comprises a clamp (125, 175) for releasably securing the connector (120) in the connector mounting location (115, 165).

3. The system (200) according to claim 1, wherein:

the frame (105, 155) defines a flat surface (130, 180) adjacent to the connector mounting location (115, 165); and

the projector mount (135, 185) is positioned so that the projector (140) projects graphical information onto the flat surface (130, 180).

4. The system (200) according to claim 3, wherein the module is configured to project, via the projector (140), a graphical user interface (500) onto the flat surface (130, 180) on the frame (105, 155) adjacent to the connector mounting location (115, 165).

5. The system (200) according to claim 4, wherein the first user input and the second user input are received via the graphical user interface (500).

6. The system (200) according to claim 3, wherein illuminating one or more pin locations of the connector (120) comprises projecting graphical information regarding the one or more pin locations onto the flat surface (130, 180).

7. The system (200) according to claim 1, wherein the module is configured to:

receive a connector schematic (214, 241), the connector schematic (214, 241) defining coordinates for the one or more pin locations; and

project, via the projector (140), an illumination dot onto each of the one or more pin locations based on (i) the position and orientation of the connector (120) and (ii) the coordinates for the one or more pin locations defined in the connector schematic (214, 241).

8. The system (200) according to claim 1, wherein the module is configured to concurrently project, via the projector (140), a plurality of illumination dots, each illumination dot being projected onto one of a plurality of pin locations of the connector (120), wherein each of the plurality of illumination dots has a distinguishing characteristic.

9. A method of inserting wire(s) into a connector (120), comprising:

providing a wire insertion apparatus (100, 150), the wire insertion apparatus (100, 150) comprising;

a frame (105, 155), the frame (105) defining a connector mounting location (115, 165); and

a projector mount (135, 185) attached to the frame (105, 155), the projector mount (135, 185) being positioned so that a projector (140) held in the projector mount (135, 185) projects graphical information onto the connector (120) when the connector (120) held by the mounting location (115, 165);

mounting the projector (140) to the projector mount;

providing a computer device (202, 224) in communication with the projector and comprising;

a processor (204, 226);

a memory (206, 228); and

a module stored in the memory (206, 228), executable by the processor (204, 226) and configured to;

control the projector (140) to project a plurality of alignment dots onto the connector (120);

move the alignment dots projected onto the connector (120) based on a first user input;

receive a second user input that the alignment dots are aligned;

determine a position and orientation of the connector (120) based on coordinates of the alignment dots; and

control the projector (140) to illuminate one or more pin locations of the connector (120) based on the position and orientation of the connector (120);

mounting the connector (120) to the connector mounting location (115, 165);

projecting, via the projector (140), the plurality of alignment dots onto the connector (120);

moving, via the computer device (202, 224), the alignment dots projected onto the connector (120) based on the first user input;

receiving, via the computer device (202, 224), the second user input that the alignment dots are aligned and, based on the second user input, determining, via the computer device (202, 224), the position and orientation of the connector (120) based on the coordinates of the alignment dots;

illuminating, via the projector (140), one or more pin locations of the connector (120) based on the position and orientation of the connector (120); and

inserting a wire into each of the one or more illuminated pin locations.

10. The method according to claim 9, wherein:

the frame (105, 155) defines a flat surface (130, 180) adjacent to the connector mounting location (115, 165); and

the projector mount (135, 185) is positioned so that the projector (140) projects graphical information onto the flat surface (130, 180).

11. The method according to claim 10, comprising projecting, via the projector (140), a graphical user interface (500) onto the flat surface (130, 180), wherein the first user input and the second user input are received via the graphical user interface (500).

12. The method according to claim 9, comprising receiving a connector schematic (214, 241), the connector schematic (214, 241) defining coordinates for the one or more pin locations;

wherein the step of illuminating one or more pin locations of the connector (120) comprises projecting, via the projector (140), an illumination dot onto each of the one or more pin locations based on (i) the position and orientation of the connector (120) and (ii) the coordinates for the one or more pin locations defined in the connector schematic (214, 241).

13. The method according to claim 9, wherein the step of illuminating one or more pin locations of the connector (120) comprises concurrently projecting, via the projector (140), a plurality of illumination dots, each illumination dot being projected onto one of a plurality of pin locations of the connector (120).