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