Method and system for error correction in automated wire contact insertion within a connector

A method for correction of automated insertion of a wire contact into a target hole of a connector, the method comprising:

• controlling a robot having an end-effector to align the wire contact with the target hole of the connector using a wire gripper of the end-effector;
• controlling the robot to advance the wire contact toward the target hole of the connector and at least partially insert the wire contact into the target hole;
• controlling the robot to cease insertion in response to a force between the wire contact and the connector exceeding a predefined value;
• determining a depth of insertion of the wire contact within the target hole of the connector;
• in response to the depth of insertion being above a predetermined depth, controlling the robot to perform a pull test of pulling the wire contact away from the connector;
• in response to the depth of insertion being below a predetermined depth:
• identifying an error condition using visual feedback;
• determining a number of corrective operations performed;
• performing an error correction operation in response to the number of corrective operations being below a predefined number;
• and
• moving the wire contact away from the target hole in response to the number of corrective operations being above the predefined number.

An apparatus comprising at least one processor and at least one memory including computer program code, the at least one memory and computer program code configured to, with the processor, cause the apparatus to at least:

• control a robot having an end-effector to align a wire contact with a target hole of a connector using a wire gripper of the end-effector;
• control the robot to advance the wire contact toward the target hole of the connector and at least partially insert the wire contact into the target hole;
• control the robot to cease insertion in response to a force between the wire contact and the connector exceeding a predefined value;
• determine a depth of insertion of the wire contact within the target hole of the connector;
• in response to the depth of insertion being above a predetermined depth, control the robot to perform a pull test of pulling the wire contact away from the connector;
• in response to the depth of insertion being below a predetermined depth:
• identify an error condition using visual feedback;
• determine a number of corrective operations performed;
• perform an error correction operation in response to the number of corrective operations being below a predefined number;
• and
• move the wire contact away from the target hole in response to the number of corrective operations being above the predefined number.