Tolerance Dataset: Mating Process of Plug-in Cable Connectors for Wire Harness Assembly Tasks
Francisco Yumbla, June-Sup Yi, Meseret Abayebas, Mahir Shafiyev, Hyungpil Moon
Journal link: https://link.springer.com/article/10.1007%2Fs11370-019-00307-5
Resume
In this research, we studied the mating tolerance of various plug-in cable connectors and provide a mating tolerance data set of 70 different connectors. This data set will be highly advantageous to industries for wire harness assembly tasks using robots. Understanding the mating tolerance is crucial for automating the mating process because it is closely related to the control specifications of a robotic manipulator. Our system uses a 2-finger Robotiq adaptive gripper attached to a 6 degree-of-freedom industrial robot (ABB Robotics) to test the mating process of wire harness assembly tasks. In addition, we use 70 types of wire harness connectors with different numbers of pins widths, lengths, and thicknesses, and various shapes, to test the mating tolerance. The results indicate that the connector mating tolerance of our data set is more generous than the repeatability of conventional industrial manipulators, and further demonstrate the suitability of the position control methods to wire harness assembly tasks.
Mating process test
Repeatability of the mating process
This section explains the test to validate the accuracy and the repeatability of the ABB robot arm of the cable in the current analysis. We use a different program path, but the final frame is the position of the female connector to the male connector at the millimeter bed. After measuring the tolerance, this test can be begun. This experiment involves moving the Robotiq Adaptive Gripper multiple times in different positions. In this experiment, the female connector always returns to the mating process (with the male connector being at the millimeter bed). The program uses 5 different robot positions with different paths. Thus, we checked the mating process 100 times, as shown in the video clip.
Tolerance Database
We used a different class of cable connectors for this experiments. Commonly, these connectors have been used in wiring harness assembly system. All connectors tested in our system and we made a tolerance database.
N. | Picture | Class | Brand | Part Number | Pines | Tolerance in Z direction(mm) |
Tolerance in X direction(mm) |
---|---|---|---|---|---|---|---|
1 | ![]() |
C1 | MOLEX | 2451320205 | 2 | 0.49 | 0.49 |
2 | ![]() |
C1 | MOLEX | 2451320405 | 4 | 0.50 | 0.45 |
3 | ![]() |
C1 | MOLEX | 2451320605 | 6 | 0.41 | 0.55 |
4 | ![]() |
C2 | MOLEX | 2451350205 | 2 | 0.63 | 0.58 |
5 | ![]() |
C2 | MOLEX | 2451350405 | 4 | 0.61 | 0.58 |
6 | ![]() |
C2 | MOLEX | 2451350605 | 6 | 0.64 | 0.66 |
7 | ![]() |
C3 | MOLEX | 0436450200 | 2 | 0.35 | 0.43 |
8 | ![]() |
C3 | MOLEX | 0436450400 | 4 | 0.43 | 0.42 |
9 | ![]() |
C3 | MOLEX | 0436450600 | 6 | 0.35 | 0.27 |
10 | ![]() |
C4 | Amphenol SINE Systems | AT2PS-CKIT | 2 | 0.70 | 1.23 |
11 | ![]() |
C4 | Amphenol SINE Systems | AT3PS-CKIT | 3 | 1.15 | 1.13 |
12 | ![]() |
C4 | Amphenol SINE Systems | AT6PS-CKIT | 6 | 1.03 | 1.05 |
13 | ![]() |
C5 | MOLEX | 0528520570 | 5 | 0.84 | 0.70 |
14 | ![]() |
C5 | MOLEX | 0528521070 | 10 | 1.13 | 0.51 |
15 | ![]() |
C5 | MOLEX | 0528521670 | 16 | 1.13 | 0.53 |
16 | ![]() |
C5 | MOLEX | 0528522070 | 20 | 1.08 | 0.53 |
17 | ![]() |
C5 | MOLEX | 0528522670 | 26 | 1.18 | 0.33 |
18 | ![]() |
C6 | Digilent | 6-pin MTE Cable | 3 | 1.00 | 1.40 |
19 | ![]() |
C6 | MOLEX | 5239-04 | 4 | 1.70 | 2.05 |
20 | ![]() |
C6 | MOLEX | 5239-05 | 5 | 1.55 | 1.90 |
21 | ![]() |
C6 | MOLEX | 5239-06 | 6 | 1.65 | 1.75 |
22 | ![]() |
C6 | MOLEX | 5239-08 | 8 | 1.60 | 2.05 |
23 | ![]() |
C6 | MOLEX | 5239-09 | 9 | 1.40 | 1.90 |
24 | ![]() |
C6 | MOLEX | 5239-10 | 10 | 1.60 | 2.00 |
25 | ![]() |
C7 | YEONHO | SMH250-05 | 5 | 1.65 | 1.20 |
26 | ![]() |
C7 | ELEPARTS | PM1802 | 2 | 1.65 | 1.25 |
27 | ![]() |
C7 | YEONHO | SMH250-04 | 4 | 1.50 | 1.00 |
28 | ![]() |
C7 | YEONHO | SMH250-08 | 8 | 1.50 | 0.95 |
29 | ![]() |
C7 | ELEPARTS | SMH250-03 | 3 | 1.45 | 0.85 |
30 | ![]() |
C7 | YEONHO | SMH250-10 | 10 | 1.55 | 0.85 |
31 | ![]() |
C7 | YEONHO | SMH250-12 | 12 | 0.68 | 0.53 |
32 | ![]() |
C7 | YEONHO | SMH250-11 | 11 | 0.65 | 0.65 |
33 | ![]() |
C7 | YEONHO | SMH250-10 | 10 | 0.77 | 0.60 |
34 | ![]() |
C7 | YEONHO | SMH250-09 | 9 | 0.73 | 0.55 |
35 | ![]() |
C7 | YEONHO | SMH250-08 | 8 | 0.80 | 0.68 |
36 | ![]() |
C7 | YEONHO | SMH250-07 | 7 | 0.77 | 0.60 |
37 | ![]() |
C7 | YEONHO | SMH250-06 | 6 | 0.70 | 0.55 |
38 | ![]() |
C7 | YEONHO | SMH250-05 | 5 | 0.68 | 0.51 |
39 | ![]() |
C7 | YEONHO | SMH250-04 | 4 | 0.73 | 0.50 |
40 | ![]() |
C7 | YEONHO | SMH250-03 | 3 | 0.75 | 0.43 |
41 | ![]() |
C7 | YEONHO | SMH250-02 | 2 | 0.78 | 0.58 |
42 | ![]() |
C8 | ELEPARTS | MO0101 | 1 | 1.10 | 1.85 |
43 | ![]() |
C8 | ELEPARTS | MO0102 | 2 | 1.60 | 1.40 |
44 | ![]() |
C8 | ELEPARTS | MO0103 | 3 | 1.65 | 1.85 |
45 | ![]() |
C8 | ELEPARTS | MO0104 | 4 | 0.95 | 1.00 |
46 | ![]() |
C9 | MOLEX | 0340620025 | 2 | 1.26 | 1.68 |
47 | ![]() |
C9 | MOLEX | 0334710206 | 2 | 1.16 | 1.01 |
48 | ![]() |
C9 | MOLEX | 0334710306 | 3 | 0.88 | 0.87 |
49 | ![]() |
C9 | MOLEX | 0334710406 | 4 | 0.63 | 0.79 |
50 | ![]() |
C10 | MOLEX | 5557-16R | 8 | 0.95 | 0.95 |
51 | ![]() |
C10 | MOLEX | 5557-10R | 10 | 0.95 | 0.75 |
52 | ![]() |
C10 | MOLEX | 5557-12R | 12 | 0.90 | 0.80 |
53 | ![]() |
C11 | ELEPARTS | PC1802 | 2 | 1.00 | 1.05 |
54 | ![]() |
C12 | ELEPARTS | PC1602 | 2 | 1.60 | 1.65 |
55 | ![]() |
C11 | ELEPARTS | PC1603 | 3 | 1.10 | 1.25 |
56 | ![]() |
C12 | ELEPARTS | PC1604 | 4 | 2.10 | 1.60 |
57 | ![]() |
C11 | ELEPARTS | PC1606 | 6 | 1.25 | 1.40 |
58 | ![]() |
C13 | DEVICEMART | DJ7021A-2.8 | 2 | 0.40 | 0.83 |
59 | ![]() |
C13 | DEVICEMART | DJ7031A-2.8 | 3 | 0.58 | 1.06 |
60 | ![]() |
C13 | DEVICEMART | DJ7041A-2.8 | 4 | 0.46 | 0.37 |
61 | ![]() |
C13 | DEVICEMART | DJ7061A-2.8 | 6 | 0.26 | 0.85 |
62 | ![]() |
C13 | DEVICEMART | DJ7091A-2.8 | 9 | 0.45 | 0.77 |
63 | ![]() |
C14 | DEVICEMART | DJ7011A-6.3 | 1 | 1.47 | 1.29 |
64 | ![]() |
C14 | DEVICEMART | DJ7021A-6.3 | 2 | 1.94 | 1.37 |
65 | ![]() |
C14 | DEVICEMART | DJ7031A-6.3 | 3 | 0.90 | 0.93 |
66 | ![]() |
C14 | DEVICEMART | DJ7041A-6.3 | 4 | 1.47 | 1.14 |
67 | ![]() |
C14 | DEVICEMART | DJ7061A-6.3 | 6 | 1.54 | 1.27 |
68 | ![]() |
C15 | DEVICEMART | DJ7031A-6.3 | 3 | 0.31 | 0.65 |
69 | ![]() |
C15 | DEVICEMART | DJ7041A-6.3 | 4 | 0.38 | 0.76 |
70 | ![]() |
C15 | DEVICEMART | DJ7061A-6.3 | 6 | 0.36 | 0.50 |