Simulated Mounting of a Flexible Wire for Automated Assembly of Vehicle Cabling Systems

Abstract

The manipulation of deformable objects poses a significant challenge for the automotive industry. In particular, the assembly of flexible cables and wire-harnesses in vehicles is still performed manually as there is yet to be a reliable and general solution for this problem. This paper presents a simple yet efficient motion planning algorithm to mount a flexible wire in an assembly jig, where the wire must traverse a set of forks in order. The algorithm uses a heuristic based on a set of control points to guide the wire’s movement. Various controlled assembly scenarios are built in simulation using MuJoCo, a physics engine that can emulate the dynamics of Deformable Linear Objects (DLO). Experimental results in simulation demonstrated that the amount and orientation of the forks has a large impact in the solution’s performance and highlighted several key ideas and challenges moving forward. Thus, this work serves as a stepping stone towards the development of more complete solutions, capable of assembling flexible items in vehicles.