Automated Connector Insertion in Automotive Wire Harness Assembly

Eureka has realized the automation of connector insertion on moving lines, a task previously regarded as extremely challenging, through its unique vision system and force-control technology.

Process

The system uses the Eureka 3D camera to detect the orientation of of a male connector moving on a slider.

The robot grips the connector and aligns it precisely with the corresponding female connector.

A force-torque sensor provides real-time feedback, allowing the robot to apply just the right amount of force during insertion, preventing pin damage or misalignment.

Challenge

When the object is not stationary, it is difficult for the robot to accurately detect its position and orientation and grasp it.
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The insertion requires strong pressure, and to perform it reliably, a delicate sense of ‘touch’ is essential.
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Solution

Conveyor Tracking: With the Eureka 3D Camera and AI technology, the robot precisely recognizes the orientation of the connector on the slider and times its grasping accurately.
Real-Time Force Control: Receiving real-time feedback from the force sensor, the robot senses contact between the male and female connectors and delicately guides the insertion.

Outcomes

‍Manual Process Automation: Achieving automation of high-precision tasks that previously relied on manual labor.
Improved Productivity and Consistency: Ensuring stable productivity through automation.
Full Automation: Integrating conveyor tracking and high-precision insertion into one seamless robotic workflow.