Abstract:
An automated wire insertion machine for inserting wires into grommet cavity locations of an electrical connector includes a controllable wire insertion robot and a processor to generate pre-generated plug maps based upon an original plug map of the grommet cavity locations and to control the wire insertion robot based upon one pre-generated plug map to insert the wires into the grommet cavity locations. The pre-generated plug maps are generated by defining a range of potential error of the grommet cavity locations that includes at least one of a potential rotational error and a potential translational error, defining an acceptable tolerance of the grommet cavity locations that includes at least one of an acceptable rotational tolerance and an acceptable translational tolerance, and calculating offset values of the grommet cavity locations based on the range of potential error and the acceptable tolerance, thereby generating the plurality of pre-generated plug maps.
Abstract:
A method of reducing entanglement of wires includes receiving, at a tray, one or more first wires of a first wire group from a wire feed system of a wire processing machine. In addition, the method includes receiving, at the tray, one or more second wires of a second wire group from the wire feed system after receiving the first wire group at the tray. The method further includes physically separating, using a separator device associated with the tray, at least a portion of the first wire group from the second wire group. The method also includes moving the second wire group relative to the first wire group, reducing movement of at least a portion of the first wire group relative to a tray surface during movement of the second wire group relative to the first wire group.
Abstract:
Systems and methods of aligning removable sensors mounted on a vehicle based upon sensor output of such sensors are described. Sensor output is collected from a removable sensor (e.g., a digital camera), and a representation of such sensor output is generated (e.g., a digital image). The representation of the sensor output is compared against a spatial template (e.g., a digital mask overlaid on the representation) to determine whether external references in the representation align with corresponding reference indicators in the spatial template. When alignment is required, the removable sensor is aligned by one or both of the following until the external references in a representation of sensor data at an updated current location align with the corresponding reference indicators in the spatial template: (i) adjusting the position of the removable sensor on the vehicle or (ii) adjusting the representation of the sensor output to simulate such repositioning.
Abstract:
A system for additively manufacturing a composite part comprises a delivery guide, movable relative to a surface. The delivery guide is configured to deposit at least a segment of a continuous flexible line along a print path. The continuous flexible line comprises a non-resin component and a thermosetting-resin component. The thermosetting-resin component comprises a first part and a second part. The non-resin component comprises a first element and a second element. The system further comprises a first resin-part applicator, configured to apply the first part to the first element, and a second resin-part applicator, configured to apply the second part to the second element. The system also comprises a feed mechanism, configured to pull the first element through the first resin-part applicator, to pull the second element through the second resin-part applicator, and to push the continuous flexible line out of the delivery guide.
Abstract:
A wire guide and a laser wire-processing device that includes a wire guide are provided. The laser wire-processing device includes a housing and an aperture in a side of the housing, wherein the aperture defines a longitudinal axis that is substantially perpendicular to the aperture. The laser wire-processing device also includes a backstop arranged in the housing and aligned with the longitudinal axis, the backstop defining a wire-contact surface in a facing relationship with the aperture. The laser wire-processing device also includes a wire guide arranged in the housing to manipulate a wire inserted through the aperture into a desired position relative to the longitudinal axis between the aperture and the backstop. The laser wire-processing device also includes a laser operable to direct a laser beam toward an insulation layer of the wire. The wire guide could be a tube arranged in the device or a backstop guide.
Abstract:
A system for additively manufacturing a composite part comprises a delivery guide and a surface, at least one of which is movable relative to another. The delivery guide is configured to deposit at least a segment of a continuous flexible line along a print path. The print path is stationary relative to the surface. The continuous flexible line comprises a non-resin component and a photopolymer-resin component that is partially cured. The system further comprises a feed mechanism configured to push the continuous flexible line through the delivery guide. The system further comprises a source of a curing energy. The source is configured to deliver the curing energy at least to a portion of the segment of the continuous flexible line after the segment of the continuous flexible line exits the delivery guide.
Abstract:
A system for additively manufacturing a composite part is disclosed. The system comprises a housing and a nozzle. The nozzle is supported by the housing. The nozzle comprises an outlet, sized to dispense a continuous flexible line. The continuous flexible line comprises a non-resin component and a photopolymer-resin component. The system also comprises a feed mechanism, supported within the housing. The feed mechanism is configured to push the continuous flexible line out of the outlet of the nozzle. The system further comprises a light source, supported by the housing. The light source is configured to deliver a light beam to the continuous flexible line after the continuous flexible line exits the outlet of the nozzle to at least partially cure the photopolymer-resin component of the continuous flexible line.
Abstract:
A system (100) comprises a delivery guide (112) movable relative to a surface (114). The delivery guide (112) is configured to deposit a continuous flexible line (106) along a print path (122) that is stationary relative to the surface (114). The system (100) further comprises a vessel (236), configured to hold a volume of a liquid photopolymer resin (252) and to apply a quantity of the liquid photopolymer resin (252) to the non-resin component (108) to create the continuous flexible line (106). The system (100) further comprises a feed mechanism (104), configured to pull the non-resin component (108) through the vessel (236) and to push the continuous flexible line (106) out of the delivery guide (112). The system (100) further comprises a source (116) of curing energy (118). The source (116) is configured to deliver the curing energy (118) at least to a portion (124) of the segment (120) of the continuous flexible line (106) after the segment (120) of the continuous flexible line (106) exits the delivery guide (112).
Abstract:
A method (400) of additively manufacturing a composite part (102) comprises applying a photopolymer resin (252) to a non-resin component (108) while pushing a continuous flexible line (106) through a delivery assembly (266). The continuous flexible line (106) comprises the non-resin component (108) and a photopolymer-resin component (110) that comprises at least some of the photopolymer resin (252) applied to the non-resin component (108). The method (400) also comprises depositing, via the delivery assembly (266), a segment (120) of the continuous flexible line (106) along a print path (122). The method (400) further comprises delivering curing energy (118) to at least a portion (124) of the segment (120) of the continuous flexible line (106) deposited along the print path (122).
Abstract:
A method (300) of additively manufacturing composite part (102) comprises depositing a segment (120) of a continuous flexible line (106) along a print path (122). The continuous flexible line (106) comprises a non-resin component (108) and further comprises a photopolymer-resin component (110) that is uncured. The method (300) further comprises delivering a predetermined or actively determined amount of curing energy (118) at least to a portion (124) of the segment (120) of the continuous flexible line (106) at a controlled rate while advancing the continuous flexible line (106) toward the print path (122) and after the segment (120) of the continuous flexible line (106) is deposited along the print path (120) to at least partially cure at least the portion (124) of the segment (120) of the continuous flexible line (106).