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www.vr-ih.com Virtual Reality & Intelligent Hardware 2019 Vol 1 Issue 6543557 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, [email protected] Received: 28 June 2019 Accepted: 4 November 2019 Supported by the National Defense Fundamental Research Foundation of China (JCKY2017204B502, JCKY2016204A502) and National Natural Science Foundation of China (51935003). Citation: Xiaodong YANG, Jianhua LIU, Naijing LV, Huanxiong XIA. A review of cable layout design and assembly simulation in virtual environments. Virtual Reality & Intelligent Hardware, 2019, 1(6): 543557 DOI: 10.1016/j.vrih.2019.11.001 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 review 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. Keywords 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 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. Furthermore, 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] ; · Review ·

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Page 1: Areview of cable layout design and assembly simulation in ...€¦ · used AR to assist with cable layout design and demonstrated real-time cable manipulation (Figure 2c and 2d)

www.vr-ih.com

Virtual Reality & Intelligent Hardware 2019 Vol 1 Issue 6:543—557

A review of cable layout design and assembly simulationin virtual environments

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

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

* Corresponding author, [email protected]: 28 June 2019 Accepted: 4 November 2019

Supported by the National Defense Fundamental Research Foundation of China (JCKY2017204B502, JCKY2016204A502)and National Natural Science Foundation of China (51935003).Citation: Xiaodong YANG, Jianhua LIU, Naijing LV, Huanxiong XIA. A review of cable layout design and assembly

simulation in virtual environments. Virtual Reality & Intelligent Hardware, 2019, 1(6): 543—557

DOI: 10.1016/j.vrih.2019.11.001

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 review 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.

Keywords 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 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. Furthermore, 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];

·Review·

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Virtual Reality & Intelligent Hardware 2019 Vol 1 Issue 6:543—557

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, as

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 Figure 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.

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 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 industrial path simulation (IPS)

software developed by the Fraunhofer Institute (Berlin, Germany) is specifically designed to resolve

Figure 1 Organization of the paper.

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Xiaodong YANG et al: A Review of Cable Layout Design and Assembly Simulation in Virtual Environmentsindustrial 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 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 (Figure 2a). 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 (Figure 2b). Based on an 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 (Figure 2c and

2d). 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.

Figure 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) and (d) Wired cables in an augmented

reality environment (Valentini et al.).

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Virtual Reality & Intelligent Hardware 2019 Vol 1 Issue 6:543—557

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, slowing the product development cycle;

thus, automatic cable layout design has become increasingly popular for automatically deriving 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

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 on 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 (Figure 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

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Xiaodong YANG et al: A Review of Cable Layout Design and Assembly Simulation in Virtual Environments

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 cable adherence constraints, improving

the efficiency and quality of automatic cable layout

(Figure 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 that are required.

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.

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 been conducted.

Given the continuous developments in robotic flexible motion planning technology, many studies have

been conducted on motion and operation planning for 1D flexible parts; these studies 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

Figure 3 Automatic wiring method of Kabul et al..

Figure 4 Automatic cable layout system of Liu et al..

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Virtual Reality & Intelligent Hardware 2019 Vol 1 Issue 6:543—557

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 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 Figure 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.

3.2 Cable manipulation planning

Cable manipulation planning is needed because

manipulation will often affect cable shape;

geometric or topologic changes can be modeledFigure 5 Sampling-based motion planning for a deformable

part (Mahoney et al.).

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Xiaodong YANG et al: A Review of Cable Layout Design and Assembly Simulation in Virtual Environmentsduring planning[44]. During cable 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 (Figure 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.

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)

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 (Figure 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.

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

Figure 6 Rope operation planning using the random

path graph method of Saha et al..

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Virtual Reality & Intelligent Hardware 2019 Vol 1 Issue 6:543—557

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 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, physical model units and harness. 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 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

550550

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Xiaodong YANG et al: A Review of Cable Layout Design and Assembly Simulation in Virtual Environmentscollision 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 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 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 (Figure 8).

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.

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Virtual Reality & Intelligent Hardware 2019 Vol 1 Issue 6:543—557

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 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 they make contact with 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 the cable-laying quality,

resulting in suboptimal electrical performance. However, evaluations of the quality of the 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.

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