RoLei - Robot-Based Installation of Deformable Cables
Installing cables is an essential step in the assembly of numerous products. Examples include hydraulic and pneumatic systems in agricultural machinery or high-voltage storage systems in electric vehicles. This process includes targeted deformation of the cables, fixing them at defined points, and connecting the cable ends using plug connections. Currently, cable installation is mostly done manually, which leads to two challenges: On the one hand, quality problems arise, such as incorrectly installed cables or false latching. On the other hand, the physical strain on employees is high due to difficult accessibility, unfavorable body postures, high monotony, and delicate tasks. This is particularly problematic for high-wage locations like Germany, especially in times of skilled labor shortages.
Automating cable installation offers the potential to address these challenges and increase the efficiency and quality of the installation process. However, with the current state of technology, it is only possible to use robotic systems for this task to a limited extent.
Objective
The overarching goal of the RoLei project is to enable a robotic system to automatically install deformable cables. This is to be achieved by combining the trajectory planning of an industrial robot with a cable physics simulation. Task-specific trajectories and necessary contact points of the robot with the cable are derived from the physics simulation. Based on the contact points, suitable gripper systems for handling the cable are designed. Subsequently, the robot trajectories are planned based on the cable trajectories and the contact points with the cable. To compensate for deviations between simulation and reality during the implementation of the trajectories, intelligent sensors are used, which are also employed for quality assurance of the installed cable.
Research Focus
- Gripping Technology: Development of a methodology for designing gripper systems for the installation of deformable cables
- Use of simulations for digital planning of cable installation: Combined consideration of robot trajectory planning and a cable physics simulation to determine optimal installation trajectories and contact points between the robot and the cable
- Performing cable installation through the use of simulations
- Error detection in the cable installation process using intelligent sensors
Consortium
The consortium consists of the Institute for Machine Tools and Industrial Management (iwb) at the Technical University of Munich, three companies (AGCO GmbH, F. X. MEILLER Fahrzeug- und Maschinenfabrik GmbH & Co KG, fleXstructures GmbH), and an associated partner (BMW Group).
Acknowledgements
The RoLei project is funded by the Bavarian State Ministry for Economic Affairs, Regional Development and Energy and is administratively managed by the project sponsor VDI/VDE Innovation + Technik GmbH. The iwb extends its sincere gratitude to all partners for their support, collaboration, and excellent cooperation in the project