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<p>Aircraft wiring harness assembly remains highly manual, and existing AR-assisted studies mainly address planar routing on formboards rather than spatial routing in confined spaces. This work presents an AR-assisted wiring harness assembly system that integrates assembly guidance and online inspection for confined-space operations. Key assembly information is extracted from engineers’ virtual assembly to generate AR guidance instructions, which are overlaid onto physical assembly locations through a marker + stereo visual-inertial joint localization method. A machine vision-based bending-radius measurement method is also developed to support online quality inspection during assembly. Functional experiments validate the proposed joint localization and bending-radius measurement methods, and a user study using a fighter jet cockpit wiring harness assembly task evaluates system usability. Compared with traditional documentation guidance, the proposed system significantly accelerates assembly, reduces assembly errors, improves perceived ease-of-use, and alleviates workers’ workload.</p>

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An augmented reality-assisted system for wiring harness assembly in confined spaces

  • 期刊论文

  • 发表日期：

    2026年7月22日

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  • Haitao Liu,
  • Zhan Wang,
  • Rongqiang Li,
  • Xiaoliang Bai

摘要

Aircraft wiring harness assembly remains highly manual, and existing AR-assisted studies mainly address planar routing on formboards rather than spatial routing in confined spaces. This work presents an AR-assisted wiring harness assembly system that integrates assembly guidance and online inspection for confined-space operations. Key assembly information is extracted from engineers’ virtual assembly to generate AR guidance instructions, which are overlaid onto physical assembly locations through a marker + stereo visual-inertial joint localization method. A machine vision-based bending-radius measurement method is also developed to support online quality inspection during assembly. Functional experiments validate the proposed joint localization and bending-radius measurement methods, and a user study using a fighter jet cockpit wiring harness assembly task evaluates system usability. Compared with traditional documentation guidance, the proposed system significantly accelerates assembly, reduces assembly errors, improves perceived ease-of-use, and alleviates workers’ workload.