Robotic manipulation of deformable linear objects (DLOs) is an active area of research, though emerging applications, like automotive wire harness installation, introduce constraints that have not been considered in prior work. Confined workspaces and limited visibility complicate prior assumptions of multi-robot manipulation and direct measurement of DLO configuration (state). This work focuses on single-arm manipulation of stiff DLOs (StDLOs) connected to form a DLO network (DLON), for which the measurements (output) are the endpoint poses of the DLON, which are subject to unknown dynamics during manipulation. To demonstrate feasibility of output-based control without state estimation, direct input-output dynamics are shown to exist by training neural network models on simulated trajectories. Output dynamics are then approximated with polynomials and found to contain well-known rigid body dynamics terms. A composite model consisting of a rigid body model and an online data-driven residual is developed, which predicts output dynamics more accurately than either model alone, and without prior experience with the system. An adaptive model predictive controller is developed with the composite model for DLON manipulation, which completes DLON installation tasks, both in simulation and with a physical automotive wire harness.

Wire harnesses are essential hardware for electronic systems in modern automotive vehicles. With a shift in the automotive industry towards electrification and autonomous driving, more and more automotive electronics are responsible for energy transmission and safety-critical functions such as maneuvering, driver assistance, and safety system. This paradigm shift places more demand on automotive wire harnesses from the safety perspective and stresses the greater importance of high-quality wire harness assembly in vehicles. However, most of the current operations of wire harness assembly are still performed manually by skilled workers, and some of the manual processes are problematic in terms of quality control and ergonomics. There is also a persistent demand in the industry to increase competitiveness and gain market share. Hence, assuring assembly quality while improving ergonomics and optimizing labor costs is desired. Robotized assembly, accomplished by robots or in human-robot collaboration, is a key enabler for fulfilling the increasingly demanding quality and safety as it enables more replicable, transparent, and comprehensible processes than completely manual operations. However, robotized assembly of wire harnesses is challenging in practical environments due to the flexibility of the deformable objects, though many preliminary automation solutions have been proposed under simplified industrial configurations. Previous research efforts have proposed the use of computer vision technology to facilitate robotized automation of wire harness assembly, enabling the robots to better perceive and manipulate the flexible wire harness. This article presents an overview of computer vision technology proposed for robotized wire harness assembly and derives research gaps that require further study to facilitate a more practical robotized assembly of wire harnesses.

The shift towards electrification and autonomous driving in the automotive industry results in more and more automotive wire harnesses being installed in modern automobiles, which stresses the great significance of guaranteeing the quality of automotive wire harness assembly. The mating of connectors is essential in the final assembly of automotive wire harnesses due to the importance of connectors on wire harness connection and signal transmission. However, the current manual operation of mating connectors leads to severe problems regarding assembly quality and ergonomics, where the robotized assembly has been considered, and different vision-based solutions have been proposed to facilitate a better perception of the robot control system on connectors. Nonetheless, there has been a lack of deep learning-based solutions for detecting automotive wire harness connectors in previous literature. This paper presents a deep learning-based connector detection for robotized automotive wire harness assembly. A dataset of twenty automotive wire harness connectors was created to train and evaluate a two-stage and a one-stage object detection model, respectively. The experiment results indicate the effectiveness of deep learning-based connector detection for automotive wire harness assembly but are limited by the design of the exteriors of connectors.

This paper addresses the challenge of industrial bin picking using entangled wire harnesses. Wire harnesses are essential in manufacturing but poses challenges in automation due to their complex geometries and propensity for entanglement. Our previous work tackled this issue by proposing a quasi-static pulling motion to separate the entangled wire harnesses. However, it still lacks sufficiency and generalization to various shapes and structures. In this paper, we deploy a dual-arm robot that can grasp, extract and disentangle wire harnesses from dense clutter using dynamic manipulation. The robot can swing to dynamically discard the entangled objects and regrasp to adjust the undesirable grasp pose. To improve the robustness and accuracy of the system, we leverage a closed-loop framework that uses haptic feedback to detect entanglement in real-time and flexibly adjust system parameters. Our bin picking system achieves an overall success rate of 91.2% in the real-world experiments using two different types of long wire harnesses. It demonstrates the effectiveness of our system in handling various wire harnesses for industrial bin picking.

Wire harnesses are essential connecting components in manufacturing industry but are challenging to be automated in industrial tasks such as bin picking. They are long, flexible and tend to get entangled when randomly placed in a bin. This makes it difficult for the robot to grasp a single one in dense clutter. Besides, training or collecting data in simulation is challenging due to the difficulties in modeling the combination of deformable and rigid components for wire harnesses. In this work, instead of directly lifting wire harnesses, we propose to grasp and extract the target following a circle-like trajectory until it is untangled. We learn a policy from real-world data that can infer grasps and separation actions from visual observation. Our policy enables the robot to efficiently pick and separate entangled wire harnesses by maximizing success rates and reducing execution time. To evaluate our policy, we present a set of real-world experiments on picking wire harnesses. Our policy achieves an overall 84.6% success rate compared with 49.2% in baseline. We also evaluate the effectiveness of our policy under different clutter scenarios using unseen types of wire harnesses. Results suggest that our approach is feasible for handling wire harnesses in industrial bin picking.

If you are not as paranoid as Musk, automatic driving may not need to divide any technical routes. But standing on the opposite side of LiDAR, Tesla may have missed the best time to develop fully autonomous driving. More info: What is LiDAR? LiDAR is not to replace millimeter-wave radar and vision, but to match with other sensors as a heterogeneous sensor. Through these three different sensors, a heterogeneous fusion can be made to ensure the overall perception security and improve sensitivity and accuracy.

If you are not as paranoid as Musk, automatic driving may not need to divide any technical routes, but only need to optimize the technology. But standing on the opposite side of lidar, Tesla may have missed the best time to develop fully autonomous driving. Lidar is not to replace millimeter-wave radar and vision, but to match with other sensors as a heterogeneous sensor. Through these three different sensors, a heterogeneous fusion can be made to ensure the overall perception security and improve sensitivity and accuracy. Different from the traditional mechanical rotary lidar, Suteng, a Chinese company mainly adopt MEMS technology, which has the advantages of small volume, easy integration, low energy consumption, and low cost.