a review of cable layout design and assembly simulation in virtual...

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Review A review of cable layout design and assembly simulation in virtual environments Xiaodong YANG, Jianhua LIU * , Naijing LV, Huanxiong XIA School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China; * Corresponding author, E-mail: [email protected] Received: xx xx 2019 Accepted: xx xx 2019 Supported by the National Defense Fundamental Research Foundation, China (JCKY2017204B502, JCKY2016204A502) and National Natural Science Foundation, China (No. 51935003) Abstract. The layout and assembly of flexible cables play important roles in the design and development of complex electromechanical products. The rationality of cable layout design and the reliability of cable assembly greatly affect product quality. In this paper, we review the methods of cable layout design, cable assembly process planning and cable assembly simulation. We first reviews research on flexible cable layout design (both interactive and automatic). Then, research on the cable assembly process planning, including cable assembly path and manipulation planning, is reviewed. Finally, cable assembly simulation is introduced, which includes general cable information, cable collision detection data, and cable assembly process modeling. Current problems and future research directions are summarized at the end of the paper. Key words. Flexible cable; layout design; assembly process planning; assembly process simulation 1 Introduction The plural "cables" is the collective term for wires, cables, and harnesses used to connect electrical components, equipment, and control devices in complex electromechanical products [1]. As such products become optically, mechanically, and electrically integrated, various types of cables transmitting both energy and signals are increasingly being used in aerospace, automotive, marine, and missile applications, among others. Cable layout design and assembly tasks are important components of electromechanical systems; these tasks are both complicated and

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Page 1: A review of cable layout design and assembly simulation in virtual …vr-ih.com/vrih/resource/latest_accept/291072482763776.pdf · 2019-11-07 · development of complex electromechanical

Review

A review of cable layout design and assembly simulation in

virtual environments

Xiaodong YANG, Jianhua LIU*, Naijing LV, Huanxiong XIA

School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China;

* Corresponding author, E-mail: [email protected]

Received: xx xx 2019 Accepted: xx xx 2019

Supported by the National Defense Fundamental Research Foundation, China

(JCKY2017204B502, JCKY2016204A502) and National Natural Science Foundation, China

(No. 51935003)

Abstract. The layout and assembly of flexible cables play important roles in the design and

development of complex electromechanical products. The rationality of cable layout design and

the reliability of cable assembly greatly affect product quality. In this paper, we review the

methods of cable layout design, cable assembly process planning and cable assembly simulation.

We first reviews research on flexible cable layout design (both interactive and automatic). Then,

research on the cable assembly process planning, including cable assembly path and manipulation

planning, is reviewed. Finally, cable assembly simulation is introduced, which includes general

cable information, cable collision detection data, and cable assembly process modeling. Current

problems and future research directions are summarized at the end of the paper.

Key words. Flexible cable; layout design; assembly process planning; assembly process

simulation

1 Introduction

The plural "cables" is the collective term for wires, cables, and harnesses used to connect

electrical components, equipment, and control devices in complex electromechanical products [1].

As such products become optically, mechanically, and electrically integrated, various types of

cables transmitting both energy and signals are increasingly being used in aerospace, automotive,

marine, and missile applications, among others. Cable layout design and assembly tasks are

important components of electromechanical systems; these tasks are both complicated and

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time-consuming. Rational cable layout design and reliable assembly are important factors in

product quality. Given the large number of cables used in complex electromechanical products,

layout design must not only consider functional cable connections, but should also save space to

facilitate assembly and maintenance, and meet engineering requirements such as electromagnetic

compatibility. As cables are flexible, entanglement and excessive deformation often occur during

operation. Therefore, cable assembly is more difficult and complicated than the assembly of rigid

components, and requires more manpower and time. Traditionally, cable layout design and

assembly relied on physical prototypes of the structural parts; however, problems in design are

discovered only after such prototypes are fabricated. Also, inappropriate routing may lead to

unwanted structural modifications. If the design proceeds via trial-and-error, the required time

may be long and the cost high [2][3]; it is also difficult to guarantee quality and reliability.

In recent years, developments in computer simulation, virtual reality (VR), and

augmented reality (AR) have greatly aided cable layout design and assembly. The use of

computers for layout design, and assembly planning and simulation, solves many of the

problems associated with traditional design methods; designers can quickly create and

simulate cables to find and resolve problems that may occur during assembly and use. This

greatly shortens the product development cycle, reduces costs, and improves product

assembly quality and reliability [4][5].

This paper focuses on cable layout design, and the cable assembly process and simulation in

virtual environments. The paper is organized as follows. In Section 2, we discuss research

progress in cable layout design. The literature on cable assembly process planning is introduced in

Section 3. Section 4 presents the literature on assembly simulation. Current problems and future

research directions are summarized in Section 5. The organization of the paper is shown in Fig. 1.

Cable layout design precedes cable assembly process planning, which in turn serves as the

basis for subsequent simulation that provides feedback on cable layout design, to guide,

verify, and optimize cable assembly.

Fig. 1. Organization of the paper

Cable layout

design

Cable assembly process

planning

Cable assembly process

simulation

Virtual environment

Basis

Feedback

Support

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2 Flexible cable layout design

Computer-aided design (CAD) can be used to generate a 3D digital prototype of the

cable layout; the layout can also be viewed in a VR environment. The process can be

considered as a human-computer interactive process or an automatic process, depending on

how the layout results are generated. The former emphasizes human experience and design

ability; the latter derives the cable layout path automatically using intelligent algorithms.

2.1 Interactive cable layout design

"Human-computer interactive cable layout design" refers to the complete simulation of cable

layout and assembly using interactive devices in a virtual environment. Several commercial CAD

software packages include cable wiring design modules [e.g., Pro/DIAGRAM, Pro/CABLING,

and Pro/ROUTING in Pro/E (PTC); UG/Wiring and UG/Harness in UG (Siemens); and ECR

(Electrical Cableway Routing) in CATIA (Dassault Systems)]. These software packages resolve

the problems associated with cable layout design to some extent, but a good deal of

human-computer interaction is required, and the physical properties of cables and layout path

optimization are not considered.

ESI developed a VR/visual design platform, IC.IDO, to aid manufacturing and

decision-making. The Route module deals with high-complexity systems and can handle dense

wiring data, allowing professional-level wiring systems to be devised. The module focuses

specifically on cable lengths after wiring. The Flexible module can be used to create and modify

wiring systems and connectors, with optimized cable flexibility and reduced deformation and

expansion. The IPS (Industrial Path Simulation) software developed by the Fraunhofer Institute

(Berlin, Germany) is specifically designed to resolve industrial path planning problems. The Cable

Simulation module [6][7] allows the layout of flexible structures, such as hoses and cable

harnesses, to be optimized; virtual assembly can also be performed. Motion can be applied to

flexible pipelines, with real-time calculation of the deformations of various materials of different

lengths. The module also calculates the forces acting on, and bending moments of, flexible

pipelines and optimizes their lengths; clips can be positioned as required.

Many researchers have developed virtual wiring systems. Park et al. [8] of Stanford

University (Stanford, CA, USA) used a multi-agent-based approach to apply parallel engineering

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to cable design. Their multi-agent prototype system is called First-Link, and their distributed agent

framework was tested in the context of aircraft cabling design. Ng and Ritchie et al. [9-15] of

Heriot-Watt University (Edinburgh, UK) developed a human-computer interactive cable wiring

system, known as CHIVE (Cable Harnessing in Virtual Environments), with an immersive VR

environment (Fig. 2(a)). A helmet display and interactive equipment, such as a 3D mouse, are

used for cable layout design in a virtual environment; the results can be checked using interference

detection to further improve cable laying efficiency. Liu et al. [16][17] of the Beijing Institute of

Technology (Beijing, China) developed the virtual assembly process planning (VAPP)

system (Fig. 2(b)). Based on analysis of cable flexibility, discrete cable control points are

modeled in a virtual environment, facilitating interactive cable layout design. Valentini et al. [18]

of the University of Rome (Rome, Italy) and Liu et al. [19] of Huazhong University of Science

and Technology (Wuhan, China) used AR to assist with cable layout design and demonstrated

real-time cable manipulation (Fig. 2(c)(d)). Wei et al. of the Chinese Academy of Engineering

Physics (Mianyang, China) [20][21] developed a virtual wiring prototyping method. Prototype

visualization based on human-computer interaction is used to lay out the cable and plan assembly.

The system includes a virtual prototype, a cable connection list, a cable interface, cable material

data, and cable layout data, among other information.

Software can be used to resolve some of the problems associated with cable layout

design; however, during actual application, interactive wiring requires considerable human

input and interference from other objects remains problematic. Most software packages do

not consider the physical properties of cables or layout optimization.

(a) (b)

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(c) (d)

Fig. 2. (a) A human-computer interactive wiring system featuring an immersive virtual reality

environment (Ritchie et al.). (b) A virtual assembly process planning system (Liu et al.). (c)(d)

Wired cables in an augmented reality environment (Valentini et al.).

2.2 Automatic cable layout design

A great deal of cable layout design work is required when fabricating complex

electromechanical products. Human-computer interactive design remains relatively inefficient,

which slows the product development cycle; thus, automatic cable layout design has become

increasingly popular, to automatically derive a cable layout path that meets the electrical

connection requirements, wiring rules, and performance criteria. The path should connect the ends

of cables and meet certain constraints. Research on automatic cable layout design can be divided

into two types. The first type is concerned with automation of the entire process; attempts have

been made to shorten the design process by establishing an empirical knowledge base, and by

analyzing and improving wiring rules. The second type of research in this field is concerned with

automatic path generation via the application of various algorithms.

The first type of research employs parallel processing, optimization algorithms, knowledge

engineering, and other technologies. Conru et al. [22][23] integrated the system proposed by Park

et al. [8] into a complete set of algorithms for 3D automation of cable layout, using parallel

engineering and automated wiring. The wiring scheme is generated automatically and a genetic

algorithm is used to optimize the wiring efficiency. However, most research focuses on wiring

automation; in-depth studies on cable path modeling are lacking. Sung et al. [24] of Heriot-Watt

University exploited current knowledge of, and practical experience with, engineering design

processes to develop an automatic design and modeling method in an immersive virtual

environment. A design task was completed online and the method was validated by designing a

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cable. Zhu et al. [25][26] of Delft University of Technology (Delft, Netherlands) applied

knowledge-based engineering (KBE) to the automatic layout of aircraft cables. Discrete

optimization techniques were employed when considering cable length and wiring area constraints.

Optimal cable paths were sought, and the method was verified in a case study of aircraft wiring.

The second type of research uses various path search algorithms to automatically generate

cable routes. Zhu et al. [27] suggested that pipeline laying should be regarded as a path planning

problem involving multiple constraints; they used cell decomposition to obtain 2D and 3D

pipeline layouts. Schafer et al. [28] of the University of Bonn (Bonn, Germany) developed an

integrated cable layout method in 3D space. Their aim was to increase packing density while also

satisfying space constraints, where the method that they designed deals principally with

orthogonal layouts. Liu and Zhou of Guilin University of Electronic Technology (Guangxi, China)

[29] investigated 3D cable wiring in an electronic machine. Using the A* algorithm and dynamic

programming, an electronic, whole-machine routing path search method was developed. First, the

wiring space was pre-processed based on certain rules. The principal wiring path was then planned.

Next, the optimal route between the interface and the main road was derived; the feasibility of the

cable route search area was determined by reference to a collision detection factor. The routing

algorithm first pre-processed the layout when searching for a path, and then obtained paths using

different search strategies. Sampling-based robotic motion planning algorithms are being

gradually applied to path-searching problems. Kabul et al. [30] of the University of North Carolina

(Chapel Hill, NC, USA) proposed a path-planning algorithm for cable layout in a complex

environment. First, a path map of the environment was generated using a variant of the PRM

algorithm, and constraint-based sampling was then performed in the contact space. The path was

modified using adaptive forward dynamics; both geometric and physical property constraints were

considered. Their algorithm is the first to simultaneously consider path planning and the physical

properties of cables, and shows good computational efficiency (Fig. 3). Liu et al. [31][32] of the

Beijing Institute of Technology used an improved motion planning algorithm to study the

automatic layout design of single- and multi-branch cables. They rapidly obtained a cable wiring

path satisfying certain constraints after improving the rapidly exploring random trees (RRT) and

probabilistic roadmap algorithm (PRM) algorithms. Liu et al. [33] of the Beijing Institute of

Technology developed an automatic cable layout method based on the "Anytime" RRT

algorithm. A magnetic attraction algorithm detecting obstacles was developed to deal with

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cable adherence constraints, improving the efficiency and quality of automatic cable layout

(Fig. 4).

Several path-search algorithms have been used to facilitate (automatic) cable layout

design and many interesting results have been reported. However, automatic cable layout

path algorithms have not been extensively researched, and are seldom used in real-world

engineering environments because of the many calculations required.

Fig. 3. The automatic wiring method of Kabul et al.

Fig. 4. The automatic cable layout system of Liu et al.

3 Cable assembly process planning

Cable layout systems focus on the final result, i.e., the assembly of cables into an

electromechanical product. Information on the final state is obtained after the cables are laid. The

assembly process involves the use of path, sequence, strapping, and fixing schemes prior to

actual assembly, based on the cable layout design results. Cable assembly path and

manipulation planning are key to successful cable assembly process planning.

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3.1 Cable assembly path planning

Cable assembly path planning deals with the manipulation constraints imposed on the

initial and final configurations. First, a stable wire configuration satisfying the manipulation

constraints is derived; second, a path between these configurations that ensures stability is

derived [34]. Assembly path planning for 1D flexible parts must include both motion and

operation planning, but few such studies have appeared. Given the continuous developments in

robotic flexible motion planning technology, many studies have begun to appear focusing on

motion and operation planning for 1D flexible parts; these works serve as references for cable

assembly path planning.

Most methods focus on planning the flexible parts. In an early study, Lamiraux and Kavraki

[35] of Rice University (Houston, TX, USA) developed a motion planning method for deformable

parts; they used random methods. Over the full range of movement, it was considered that both

ends of the flexible part were constrained by the operation, and collisions were avoided principally

by deformation of the flexible part. This differed from earlier motion planning approaches used to

model rigid parts and hinged robots, and can be applied to flexible panels, tubes, and cables, as

well as in the medical field. Bayazit et al. [36] of Texas A&M University (College Station, TX,

USA) developed a motion planning method for deformable robots based on a random path graph

algorithm. First, a rough path was generated, wherein collisions were eliminated via robot

deformation. Eventually, a feasible path was generated, with consideration of the physical

properties of the deformable parts. Rodriguez et al. [37] established a framework for path planning

in a fully elastic deformation environment; both the planning object and the environment were

deformable. Their motion planning algorithm was based on the RRT algorithm. Mikchevitch et al.

[38][39] of the Grenoble Institute of Technology (Grenoble, France) simulated the disassembly of

flexible parts using VR and real-world or mechanical models. A two-layer system was used to

control the model, allowing users to precisely perform virtual assembly.

Other researchers have used path planning algorithms (such as sampling-based

algorithms) based on deformation of the flexible part. Moll, of the University of South

Carolina (Columbo, SC, USA), and Kavraki of Rice University [34] developed path planning

methods for deformable linear objects based on sampling path graphs. Stable configurations were

obtained by drawing minimum energy curves. An intermediate configuration was used to analyze

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different configurations. Their method can be used for cable layout, to study surgical sutures, and

to develop snake-shaped robots. Gayle et al. [40][41] of the University of North Carolina

developed a path planning algorithm for flexible robots. Their algorithm fully considered both

geometric and physical constraints; a novel collision detection algorithm was also derived. The

path is calculated using a centerline-based method that allows the robot to obtain the final

configuration. Kabul et al. [30] also employed this method, using a variant of the PRM algorithm

to generate the initial path; the final non-interference path was obtained using adaptive forward

dynamics. However, these motion planning methods are used primarily in the layout design phase

rather than the assembly phase. Mahoney et al. [42] of Utah University (Salt Lake City, UT, USA)

used principal component analysis to reduce the dimensions of the deformable motion planning

problem; their approach considered both computational efficiency and physical properties. A

sampling-based motion planning method using a deformable robot was proposed and tested on

various deformable parts. A slender deformable rod was employed, which was very similar to

short flexible cables. As shown in Fig. 5, the end constraint of the object and the energy

constraints of deformation must be considered during planning. Liu et al. [43] of the Beijing

Institute of Technology proposed a short-cable assembly path planning method based on

low-dimensional equilibrium sampling. A "guide path" was used to reduce the dimensions of

path planning. In the low-dimensional space along the guide path, random sampling was

combined with data at both ends of the cable and a path map was then constructed; finally, a

feasible assembly path was found by searching the map.

Fig. 5. Sampling-based motion planning for a deformable part (Mahoney et al).

3.2 Cable manipulation planning

Cable manipulation planning is needed because manipulation will often affect cable

shape; geometric or topologic changes can be modeled during planning [44]. During cable

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assembly, the end or middle of the cable is carried by an operator or clamped by a robot; to date,

research has focused on model-based manipulation planning. In particular, cable

knotting/unknotting has attracted attention. The hand-eye system proposed by Inaba and Inoue of

the University of Tokyo (Tokyo, Japan) [45] was earlier used for rope piercing and knotting. Using

feedback provided by the visual system, the robot successfully manipulated flexible ropes. Brown

et al. [46] of Stanford University used a real-time, multi-body, fixed-length geometric model of

rope-like objects such as surgical sutures, and successfully performed a virtual operation. Saha

and Isto [47] used a random path graph method to solve the manipulation planning problem for a

deformable linear object; in their method, which does not use a specific physical model, flexible

ropes are manipulated by a dual-arm robot (Fig. 6). Other knotting studies [48-51] have explored

motion planning, virtual surgery, and winding. Cable shape prediction during robotic

manipulation may pose a problem. For example, Papacharalampopoulos [52][53] used a

higher-order analytical model that considered mechanical behavior to estimate cable shape

during robotic manipulation. Collisions between cables and rigid parts were detected

according to a quasi-static approach.

Fig. 6. Rope operation planning using the random path graph method of Saha et al.

In the context of automatic assembly of deformable parts, Zheng et al. [54] of Ohio State

University (Columbus, OH, USA) performed a study on the insertion of deformable beams into

rigid holes, but the applications were relatively limited. Asano et al. [55] of Osaka University

(Osaka, Japan) performed a study on automatic assembly manipulation planning of strip circuit

boards. The minimum potential energy principle was applied to evaluate board deformation, from

the initial to the target shape. Hermansson et al. [56] of the Fraunhofer-Chalmers Center

(Gothenburg, Sweden) developed a method for automatic path planning of cable (wire) harness

installations in cars. The contact problem was addressed by adding a handle, and the reverse

disassembly path served as the assembly path. An industrial case study revealed that the

calculation speed was high. Roussel et al. [57][58] of the University of Illinois (Chicago, IL, USA)

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performed inextensible/extensible elastic rod operation planning; the operator grasped one or both

ends of the rod and the planning path was found based on a sampling method (Fig. 7). Mukadam

et al. [59] performed manipulation planning of multiple grippers (for elastic rods) in a 2D plane,

and determined the highest and lowest numbers of grippers required to maintain the equilibrium

states.

Fig. 7. Sampling-based elastic rod path planning (Roussel et al.).

In summary, motion or manipulation planning involving cable-like flexible parts uses

flexible body models, and various algorithms and collision detection methods, to generate

paths differing in deformation state.

4 Cable assembly process simulation

“Cable assembly process simulation” is used principally for formulating, verifying, and

optimizing cable assembly. Animations can be used in workshops for operator training and

collaborative design. Models of cable assembly including general cable information and cable

collision detection information are required [60].

4.1 Cable information models

The “cable information model” produces data on cable topology, geometry, and

physical characteristics for virtual assembly simulation. Physical and collision detection

models depend on the cable information model. Shang et al. [61] divided a cable into a series of

basic elements, and established relationships among them using subordinate and graph theory. Wei

et al. [20] devised electrical, topologic and geometric cable models, and derived various types of

cable information. Wang [62] recorded cable information taking the wire as the basic unit; the data

for all wires were then combined to provide an overview of the cable. Liu et al. [63] considered

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the physical, geometric, topologic, logical connection, and material aspects of cables in detail to

establish an integrated model. Yang et al. [64] considered cables in terms of operational

constraints, branch points, sub-cable segments, and physical model units. Five basic operational

constraints imposed by cables during assembly were considered, and cable information models

were generated using algorithms such as the breadth-first search.

In general, cable information models consider basic elements, i.e., cable attributes,

which differ depending on the particular requirements and applications; connections are

then established between the elements. However, current cable information models do not

incorporate operational constraints during assembly, and do not convert 3D cable models

built using commercial software into information models that can be used for simulation.

4.2 Cable collision detection

Cable collision detection refers to cable interference with other objects (or itself) during

assembly. This is a major problem that virtual assembly must address. Accurate collision

detection improves the authenticity of a virtual environment and enhances immersion therein

[65][66]. During laying, cables often collide with rigid structures, other cables, and pipes. Flexible

cables self-collide when handled or manipulated by tools. These collisions wear (and eventually

detach) the outer layer, compromising reliability [67]. Elimination of such interference is essential

during cable assembly simulation. Cable paths must be checked for interference. For this purpose,

a collision detection model is essential. Many useful algorithms have been developed [68][69];

these include bounding volume hierarchy (BVH), space decomposition, distance field, image

space, and intelligent algorithms [70]. The BVH algorithm is one of the most commonly used;

the bounding volume may be an axis-aligned bounding box (AABB), an oriented bounding

box (OBB), a sphere, a discrete orientation polytope (K-DOP), or a convex hull, among other

forms. However, most algorithms deal with rigid parts and collisions with flexible objects such as

cables are poorly detected. Inspired by the axisymmetric characteristics of cables, Loock et al. [71]

solved the collision problem between cables and environmental objects to determine the distances

between mass points and objects, and thus the collision status. This method detects other cables

and non-cable structures, but is limited in terms of self-collision detection. Wang et al. [72]

sampled objects to be detected, established feature pairs in 2D space, and solved the collision

detection problem to optimize the number of feature pairs using a particle swarm algorithm. The

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algorithm is very flexible, but may not detect all collision pairs. Roy et al. [73] studied collisions

involving the reins used to connect underwater robots. First, a global optimization method was

used to determine the (approximate) minimal separation distance between any two reins. Local

optimization was then employed to derive accurate separation distances. If a collision is detected,

the algorithm calculates the contact force according to the region of interference. Shellshear [74]

studied the self-collision detection of deformable linear cables using a 1D “sweep-pruning”

algorithm. Compared to other self-collision detection algorithms, pruning was faster and could

detect collisions between two different types of object (cables and structural parts). Using a cable

mass-spring-damping model, Xie et al. [75] developed an accurate layered algorithm for detecting

cable collisions, and evaluated the response in terms of the physical characteristics of cables.

Huang et al. [76] reported that cable detection was highly memory-intensive, and developed a

large-step optimization algorithm to reduce memory consumption. To avoid stick and jitter,

various mathematical methods were used to optimize performance, although this proved difficult.

During a collision, the basic geometric elements of a flexible cable will change; thus,

rigid body collision detection algorithms cannot be applied to flexible cables. However,

refreshing geometric data is time-consuming, so real-time simulation is difficult. More

efficient algorithms for detecting flexible cable collisions are required [77].

4.3 Cable assembly process modeling

Virtual assembly process simulation can be used to further develop and optimize cable

assembly, where actual assembly is simulated and "assemblability" is evaluated. Given the

large number of flexible cables that must be assembled when fabricating complex

electromechanical products, cables not only change in terms of position, but also in shape. A cable

assembly process model is required to describe the assembly process and drive “virtual solid

modeling”, which is important for demonstration purposes.

Liu et al. [67] recorded the spatial positions of discrete cable points over time using the "path

key point" approach, and encoded path movements as "paths to describe cable movement in real

time. Shang et al. [78] used an improved hierarchical task chain model to unify the description of

a rigid-flexible hybrid assembly process. Wei et al. [21] divided assembly units into "rigid parts"

and "flexible cables", recorded assembly actions sequentially, and simultaneously moved cables

and operated electrical parts such as joints. Zhang [79] decomposed cable assembly into three

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parts: plugging in the electrical cable connector, fixed operation of the cable bundle, and

deformation. Assembly was considered as the reverse of disassembly, according to the "detachable

and installable" concept. Wang [58] recorded the positions of cable parts at key moments in an

assembly animation and thus achieved visual continuity. Considering the flexibility of

deformable linear objects, Lv et al. [80][81] established a real-time physical model of a cable

using the extension mass-spring and Cosserat elastic rod models. Both models consider cable

stretching, bending, and twisting, ensuring authentic cable assembly process simulations (Fig.

8).

(a) (b)

Fig. 8. (a) Cable deformation evaluated using an extension mass-spring model (Lv et al.). (b)

Cable deformation evaluated using the Cosserat elastic rod model (Lv et al.).

In summary, the principal difficulty during modeling of the cable assembly process is

cable flexibility. Cables change in terms of both orientation and shape during operation, and

rigid parts, such as connectors and clamps, are often assembled together with flexible cables.

Efficient recording of process information is key for cable assembly simulations.

5 Conclusions and future work

In summary, many researchers are conducting studies on new technologies, methods, and

tools for flexible cable layout design, and cable assembly process planning and simulation.

However, these studies are still exploratory in nature and few real-world applications have

emerged. The current problems and future research directions can be summarized as follows:

(1) Technology for automatically deriving cable layouts

Using computers to generate cable routing and assembly paths greatly improves design

efficiency. However, the research in this area remains immature and the efficiency of path search

algorithms must be improved. Engineering constraints and the physical properties of cables must

be considered when optimizing the paths. Cable layout and assembly processes require further

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improvement.

(2) Rigid-flexible hybrid assembly planning technology

Complex electromechanical products are assembled from rigid parts and flexible cables.

Given their widespread use, it is very important to plan the assembly sequence and path of cables.

In addition, potential collisions during assembly must be considered. Collisions can occur between

rigid parts, rigid parts and flexible cables, and two or more cables. Cables deform when contacting

surrounding objects, so cable flexibility must be considered during assembly.

(3) Evaluation of cable-laying quality evaluation

Cable layout design and assembly process planning affect the final laying results and cable

life during operation. Inappropriate layout design and non-standard assembly can reduce cable-

laying quality, such that electrical performance may suffer. However, evaluations of the quality of

cable layout and assembly still depend on the experience of technicians and/or the experimental

method used. A standard scientific quality-evaluation system is required.

(4) VR, AR and force feedback

According to the continuous developments in VR, AR, force feedback, and the associated

hardware, these methods are now used for cable layout design and assembly planning. The

immersion afforded by virtual environments enhances realism and allows knowledge and

experience to be fully exploited, which in turn improves the efficiency and quality of cable layout

and assembly. Future developments in virtual environments, and the associated hardware and

software, will further enhance cable layout design and assembly planning.

(The English in this paper has been checked by at least two professional editors, both native

speakers of English. For a certificate, please see: http://www.textcheck.com/certificate/7T9giG)

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