Method and system for error correction in automated wire contact insertion within a connector

1. A system for correction of automated insertion of a wire contact into a target hole of a connector, the system comprising:

a robot having an end-effector, wherein the end-effector comprises a wire gripper;

a computing device, wherein the computing device is configured to:

control the robot to align the wire contact with the target hole of the connector;

control the robot to advance the wire contact toward the target hole of the connector and at least partially insert the wire contact into the target hole;

control the robot to cease insertion in response to a force between the wire contact and the connector exceeding a predefined value;

determine a depth of insertion of the wire contact within the target hole of the connector, wherein the depth of insertion of the wire contact into the target hole of the connector is determined based on an initial distance of the wire contact to a surface of the connector and a traveled distance of the robot;

in response to the depth of insertion being above a predetermined depth, control the robot to perform a pull test of pulling the wire contact away from the connector;

in response to the depth of insertion being below a predetermined depth:

identify an error condition using visual feedback;

determine a number of corrective operations performed;

perform an error correction operation in response to the number of corrective operations being below a predefined number; and

move the wire contact away from the target hole in response to the number of corrective operations being above the predefined number.

2. The system of claim 1 , wherein the computing device configured to perform an error correction operation comprises the computing device configured to:

control the robot to adjust an orientation of the wire contact to be oriented perpendicular to a front surface of the connector; and

control the robot to re-insert the wire contact into the target hole of the connector.

3. The system of claim 2 , wherein the computing device configured to adjust the orientation of the wire contact to be oriented perpendicular to the front surface of the connector comprises the computing device configured to:

determine the orientation of the wire contact relative to the connector;

project the orientation of the wire contact onto a plane perpendicular to an orientation of the wire gripper to identify a resulting vector; and

control the robot to adjust the orientation of the wire contact according to the resulting vector to be oriented perpendicular to the front surface of the connector.

4. The system of claim 2 , wherein the computing device configured to adjust the orientation of the wire contact to be oriented perpendicular to the front surface of the connector comprises the computing device configured to:

determine the orientation of the wire contact relative to the connector;

project the orientation of the wire contact onto a plane perpendicular to an orientation of the wire gripper to identify a resulting vector;

increase the resulting vector by a predetermined amount; and

control the robot to adjust the orientation of the wire contact according to the increased resulting vector to be oriented perpendicular to the front surface of the connector.

5. The system of claim 1 , wherein the computing device configured to move the wire contact away from the target hole further comprises the computing device configured to:

control the robot to re-align the wire contact with the target hole;

control the robot to advance the wire contact toward the target hole of the connector and at least partially insert the wire contact into the target hole;

control the robot to cease insertion in response to a force between the wire contact and the connector exceeding a predefined value;

determine a new depth of insertion of the wire contact within the target hole of the connector;

in response to the new depth of insertion being above a predetermined depth, control the robot to perform a pull test of pulling the wire contact away from the connector; and

provide for indication of successful insertion of the wire contact into the target hole of the connector in response to the pull test satisfying predetermined criteria.

6. The system of claim 5 , wherein the predetermined criteria comprises movement of the wire contact less than a predefined amount out of the target hole in response to a pull force applied to the wire contact of at least a predefined force.

7. The system of claim 1 , wherein the end-effector further comprises one or more image acquisition devices for capturing images of the wire contact and the connector from at least two different angles.

8. The system of claim 7 , wherein the computing device configured to control the robot to align the wire contact with the target hole of the connector comprises the computing device configured to:

acquire images from at least two different angles using the one or more image acquisition devices;

identify a location of the target hole;

identify an alignment direction to align the wire contact with the target hole of the connector; and

control the robot to move the wire contact in the alignment direction in a plane orthogonal to an axis along which the wire contact extends.

9. The system of claim 1 , wherein the initial distance of the wire contact to the surface of the connector is established using images of the wire contact and the connector from at least two different angles.

10. A method for correction of automated insertion of a wire contact into a target hole of a connector, the method comprising:

controlling a robot having an end-effector to align the wire contact with the target hole of the connector using a wire gripper of the end-effector;

controlling the robot to advance the wire contact toward the target hole of the connector and at least partially insert the wire contact into the target hole;

controlling the robot to cease insertion in response to a force between the wire contact and the connector exceeding a predefined value;

determining a depth of insertion of the wire contact within the target hole of the connector, wherein the depth of insertion of the wire contact into the target hole of the connector is determined based on an initial distance of the wire contact to a surface of the connector and a traveled distance of the robot;

in response to the depth of insertion being above a predetermined depth, controlling the robot to perform a pull test of pulling the wire contact away from the connector;

in response to the depth of insertion being below a predetermined depth:

identifying an error condition using visual feedback;

determining a number of corrective operations performed;

performing an error correction operation in response to the number of corrective operations being below a predefined number; and

moving the wire contact away from the target hole in response to the number of corrective operations being above the predefined number.

11. The method of claim 10 , wherein performing an error correction operation comprises:

controlling the robot to adjust an orientation of the wire contact to be oriented perpendicular to a front surface of the connector; and

controlling the robot to re-insert the wire contact into the target hole of the connector.

12. The method of claim 11 , wherein adjusting the orientation of the wire contact to be oriented perpendicular to the front surface of the connector comprises:

determining the orientation of the wire contact relative to the connector;

projecting the orientation of the wire contact onto a plane perpendicular to an orientation of the wire gripper to identify a resulting vector; and

controlling the robot to adjust the orientation of the wire contact according to the resulting vector to be oriented perpendicular to the front surface of the connector.

13. The method of claim 11 , wherein adjusting the orientation of the wire contact to be oriented perpendicular to the front surface of the connector comprises:

determining the orientation of the wire contact relative to the connector;

projecting the orientation of the wire contact onto a plane perpendicular to an orientation of the wire gripper to identify a resulting vector;

increasing the resulting vector by a predetermined amount; and

controlling the robot to adjust the orientation of the wire contact according to the increased resulting vector to be oriented perpendicular to the front surface of the connector.

14. The method of claim 10 , wherein moving the wire contact away from the target hole further comprises:

controlling the robot to re-align the wire contact with the target hole;

controlling the robot to advance the wire contact toward the target hole of the connector and at least partially insert the wire contact into the target hole;

controlling the robot to cease insertion in response to a force between the wire contact and the connector exceeding a predefined value;

determining a new depth of insertion of the wire contact within the target hole of the connector;

in response to the new depth of insertion being above a predetermined depth, controlling the robot to perform a pull test of pulling the wire contact away from the connector; and

providing for indication of successful insertion of the wire contact into the target hole of the connector in response to the pull test satisfying predetermined criteria.

15. An apparatus comprising at least one processor and at least one memory including computer program code, the at least one memory and computer program code configured to, with the processor, cause the apparatus to at least:

control a robot having an end-effector to align a wire contact with a target hole of a connector using a wire gripper of the end-effector;

control the robot to advance the wire contact toward the target hole of the connector and at least partially insert the wire contact into the target hole;

control the robot to cease insertion in response to a force between the wire contact and the connector exceeding a predefined value;

determine a depth of insertion of the wire contact within the target hole of the connector, wherein the depth of insertion of the wire contact into the target hole of the connector is determined based on an initial distance of the wire contact to a surface of the connector and a traveled distance of the robot;

in response to the depth of insertion being above a predetermined depth, control the robot to perform a pull test of pulling the wire contact away from the connector;

in response to the depth of insertion being below a predetermined depth:

identify an error condition using visual feedback;

determine a number of corrective operations performed;

perform an error correction operation in response to the number of corrective operations being below a predefined number; and

move the wire contact away from the target hole in response to the number of corrective operations being above the predefined number.

16. The apparatus of claim 15 , wherein causing the apparatus to perform an error correction operation comprises causing the apparatus to:

control the robot to adjust an orientation of the wire contact to be oriented perpendicular to a front surface of the connector; and

control the robot to re-insert the wire contact into the target hole of the connector.

17. The apparatus of claim 16 , wherein causing the apparatus to adjust the orientation of the wire contact to be oriented perpendicular to the front surface of the connector comprises causing the apparatus to:

determine the orientation of the wire contact relative to the connector;

project the orientation of the wire contact onto a plane perpendicular to an orientation of the wire gripper to identify a resulting vector; and

control the robot to adjust the orientation of the wire contact according to the resulting vector to be oriented perpendicular to the front surface of the connector.

18. The apparatus of claim 15 , wherein causing the apparatus to control the robot to align the wire contact with the target hole of the connector comprises causing the apparatus to:

acquire images from at least two different angles using one or more image acquisition devices;

identify a location of the target hole;

identify an alignment direction to align the wire contact with the target hole of the connector; and

control the robot to move the wire contact in the alignment direction in a plane orthogonal to an axis along which the wire contact extends.

19. The apparatus of claim 15 , wherein causing the apparatus to move the wire contact away from the target hole further comprises causing the apparatus to:

control the robot to re-align the wire contact with the target hole;

control the robot to advance the wire contact toward the target hole of the connector and at least partially insert the wire contact into the target hole;

control the robot to cease insertion in response to a force between the wire contact and the connector exceeding a predefined value;

determine a new depth of insertion of the wire contact within the target hole of the connector;

in response to the new depth of insertion being above a predetermined depth, control the robot to perform a pull test of pulling the wire contact away from the connector; and

provide for indication of successful insertion of the wire contact into the target hole of the connector in response to the pull test satisfying predetermined criteria.