Automated Terminal-to-Housing Assembly System for Flat Ribbon Cable Harness
Authors: Eunkyu Choi, Joonho Seo, Seungmin Lee, Seokhwan Jeong
Abstract
This paper presents a sensor-minimal automated assembly system for bidirectional single-row flat ribbon cable harnesses (FRCHs). Unlike conventional peg-in-hole or single-terminal insertion tasks, FRCH assembly involves mechanically coupled multi-terminal insertion under flexible and dense geometric constraints. To address this problem, the proposed system performs the assembly through a purely mechanical sequence consisting of Cable Alignment, Lean & Slide, Weaving, and Clamping, without relying on active sensing or vision. Each mechanism is designed to progressively reduce correlated terminal misalignment, insertion interference, and instability before final locking. Experiments on bidirectional single-row FRCHs achieved an 83.75% end-to-end process success rate over 80 trials, with success rates of 85.0% and 82.5% in the first and second halves, respectively. The cycle time was 33 s under half-speed operation. To the best of our knowledge, this work presents the first automated prototype for FRCH terminal-to-housing assembly for multi-pin housings.
CableDex is a computer vision system that addresses the time-consuming and inaccurate manual measurement of cable length on industrial reels from a single photograph captured with a mobile phone. The system combines camera calibration, instance segmentation, pose estimation, and volumetric calculation to estimate the cable length across five different reel types and various cable sizes. This system is based on an instance segmentation model trained on 1,000 manually annotated images, achieving 99.5% mAP50 with an inference time of 5.66 ms per image. Evaluated on 75 reels across five reel types, the system achieves a MAPE of 4.90%, within the 10% error tolerance commonly accepted in industrial cable-reel measurement. The demonstration presents the end-to-end pipeline, from reel label scanning and image capture to segmentation and length estimation, through the mobile application.
Francisco Guillén, Ricardo Almeida, Bruno Silva +1
In flexible assembly systems, existing task planning methods require a time-consuming configuration process by multiple experts to establish a production line for a new product. To address this challenge, we propose a multi-agent based task planning framework for flexible assembly systems, denoted as AssemPlanner. It takes tasks described in natural language as input, which are then converted into actionable sequential production operations. It comprises several specialized agents, including SchedAgent , KnowledgeAgent, LineBalanceAgent, and a scene graph. Within the proposed framework, SchedAgent serves as the central reasoning engine. Departing from traditional static pipelines, AssemPlanner utilizes a ReAct-based SchedAgent to adaptively adjust actions via multi-agent feedback. By observing the feedback from KnowledgeAgent, LineBalanceAgent, and the scene graph, it autonomously resolves complex industrial process constraints. To facilitate reproducibility, all code and datasets are released at https://github.com/chz332/Assemplanner.
Robotic fabric manipulation remains challenging due to fabric deformability and occlusions from wrinkles and the manipulator. This paper defines Random-to-Target Fabric Flattening (RTFF) as the task of bringing a randomly wrinkled fabric to an arbitrary user-specified wrinkle-free target pose. RTFF requires simultaneous flattening and pose alignment, where the two objectives are inherently coupled since flattening the fabric displaces its pose, while realigning it tends to introduce wrinkles. To solve this task, this paper anchors both the current and target fabric states to the same template mesh, enabling direct vertex-level wrinkle and pose assessment without registration. Building on this representation, a hybrid Imitation Learning--Visual Servoing (IL--VS) RTFF policy is proposed. A novel Mesh Action Chunking Transformer (MACT) leverages structured mesh observations to achieve goal-conditioned coarse alignment from a compact demonstration set, after which VS ensures precise convergence to the target. The policy is validated on a real dual-arm teleoperation system, demonstrating precise alignment to unseen target poses, fabric types, and scales. Code and videos: https://kaitang98.github.io/RTFF_Policy/