Extraction, Segmentation, and 3D Reconstruction of Wire Harnesses from Point Clouds for Robot Motion Planning

Accurate collision detection in off-line robot simulation is essential for ensuring safety in modern manufacturing. However, current simulation environments often neglect flexible components such as wire harnesses, which are attached to articulated robots with irregular slack to accommodate motion. Because these components are rarely modeled in CAD, the absence of accurate 3D harness models leads to discrepancies between simulated and actual robot behavior, which sometimes result in physical interference or damage. This paper addresses this limitation by introducing a fully automated framework for extracting, segmenting, and reconstructing 3D wire-harness models directly from dense, partially occluded point clouds captured by terrestrial laser scanners. The key contribution lies in a motion-aware segmentation strategy that classifies harnesses into static and dynamic parts based on their physical attachment to robot links, enabling realistic motion simulation. To reconstruct complex geometries from incomplete data, we further propose a dual reconstruction scheme: an OBB-tree-based method for robust centerline recovery of unbranched cables and a Reeb-graph-based method for preserving topological consistency in branched structures. The experimental results on multiple industrial robots demonstrate that the proposed approach can generate high-fidelity 3D harness models suitable for collision detection and digital-twin simulation, even under severe data occlusions. These findings close a long-standing gap between geometric sensing and physics-based robot simulation in real factory environments.