Semi-automatic terminal crimping apparatus and method thereof

Abstract

This invention relates to the field of wire harness processing equipment technology, specifically a semi-automatic terminal crimping device and method. The invention includes a crimping machine housing with a first process port on its side wall for inserting the wire harness. Inside the housing are a wire harness clamping mechanism, a waterproof plug insertion assembly, and a wire stripping assembly. The wire stripping assembly includes a cutter for cutting the wire harness insulation. This invention utilizes a V-shaped transmission frame at the end of a V-shaped handpiece to create a linkage with a contact rod on a first V-shaped positioning frame. During the waterproof plug's pushing process, the positioning frame is synchronously driven to move aside, ensuring smooth insertion of the waterproof plug. After the waterproof plug reaches a preset position, only the contact constraint on the positioning frame is released; there is no need to completely remove it from the insertion mechanism. A return spring drives the first V-shaped positioning frame to automatically return and close, reserving ample operating space for the wire stripping and crimping processes while providing continuous rigid axial restraint for the waterproof plug.

Description

Technical Field

[0001] This invention relates to the field of wire harness processing equipment technology, specifically a semi-automatic terminal crimping device and method. Background Technology

[0002] With the continuous improvement of electrical connection reliability requirements in fields such as new energy vehicles, high-end industrial control, and rail transportation, and the ongoing iterative upgrades of manufacturing technologies for new electrical contact precious metal materials, waterproof wire harnesses equipped with terminals made from such materials have become core components of high-protection-level electrical systems. The waterproof sealing performance and terminal electrical contact performance of these wire harnesses directly determine the operational safety and service life of the electrical system, while the process precision and equipment performance in the wire harness processing stage are the fundamental prerequisites for ensuring these two core performance characteristics. In flexible processing scenarios with small to medium batches and multiple varieties, semi-automatic terminal crimping equipment is the core equipment for waterproof wire harness processing. The performance of its waterproof plug insertion mechanism directly determines the waterproof reliability and terminal electrical contact performance stability of the finished wire harness.

[0003] Currently, most semi-automatic waterproof terminal crimping equipment uses a push rod type plug insertion mechanism as the core structure for inserting waterproof plugs: this type of mechanism pushes the waterproof plug along the wire harness axis to the preset processing position by a push rod, and then the push rod immediately and completely removes its constraint on the wire harness and the waterproof plug, leaving room for subsequent wire stripping and terminal crimping processes.

[0004] However, this type of push-rod type plug insertion method has an inherent technical flaw that cannot be overcome: the waterproof plug is made of elastic materials such as rubber or silicone. During the insertion process, its inner wall continuously slides against the wire harness insulation, and its front end rigidly contacts the positioning structure, resulting in compression deformation and the accumulation of axial rebound force. When the push rod is completely removed from the constraint, the rebound force accumulated in the waterproof plug is released instantaneously, directly causing the waterproof plug to spring back and shift along the wire harness axial direction, and even causing the end to flip or the radial to tilt. After the waterproof plug deviates from the preset processing position, it will directly intrude into the working range of the cutting tool in the subsequent wire stripping process, causing the wire stripper to directly cut and damage the waterproof plug during the cutting of the wire harness insulation, resulting in irreversible damage to the waterproof sealing structure and causing the waterproof performance of the finished wire harness to completely fail. Summary of the Invention

[0005] The purpose of this invention is to provide a semi-automatic terminal crimping device and method to solve the problems mentioned in the background art.

[0006] The objective of this invention can be achieved through the following technical solutions: A semi-automatic terminal crimping device, preferably, includes a crimping machine housing, the side wall of which has a first process port for inserting wire harnesses, and the inside of the crimping machine housing is provided with a wire harness clamping mechanism, a waterproof plug insertion assembly, and a wire stripping assembly, the wire stripping assembly including a switch for cutting the insulation of the wire harness. The wire harness clamping mechanism includes a pair of first V-shaped positioning frames arranged vertically opposite each other. One end of the first V-shaped positioning frame is fixed with a T-shaped slide rod. The T-shaped slide rod is slidably connected to the U-shaped mounting frame. A return spring is sleeved on the outer periphery of the T-shaped slide rod. The two ends of the return spring abut against the first V-shaped positioning frame and the U-shaped mounting frame, respectively. The waterproof plug installation assembly includes a V-shaped palm frame that can reciprocate along the axial direction of the wire harness. A V-shaped transmission frame is fixed to the end of the V-shaped palm frame. A first V-shaped positioning frame is rotatably connected to an abutment rod adapted to the V-shaped transmission frame at one end facing the V-shaped transmission frame. When the V-shaped palm frame pushes the waterproof plug to move along the axial direction of the wire harness, the first V-shaped positioning frame is moved along the guiding direction of the T-shaped slide rod by the contacting cooperation between the V-shaped transmission frame and the contact rod, so that the waterproof plug passes through the area between the two first V-shaped positioning frames. After the waterproof plug moves to the preset position, the V-shaped transmission frame disengages from the contact rod, and the return spring rebounds, causing the first V-shaped positioning frame to return and close, clamping the end of the wire harness while axially limiting the waterproof plug and physically isolating the waterproof plug from the switch.

[0007] Preferably, the wire harness clamping mechanism further includes a first electric push rod, a second V-shaped positioning frame, and a third V-shaped positioning frame; The second V-shaped positioning frame is fixed to one end of the inner side of the first process port, and the third V-shaped positioning frame is slidably disposed at the other end of the inner side of the first process port. The second V-shaped positioning frame and the third V-shaped positioning frame are arranged opposite each other on the left and right. The output end of the first electric push rod is fixedly connected to the third V-shaped positioning frame and is used to drive the third V-shaped positioning frame to move closer to the second V-shaped positioning frame to form a centering clamp on the middle section of the wire harness.

[0008] Preferably, the output end of the first electric actuator is also symmetrically fixed with two opposing Z-shaped guide frames, and a transmission pulley is rotatably connected to one side of the U-shaped mounting bracket, the transmission pulley being slidably embedded inside the Z-shaped guide frame; While the first electric actuator drives the third V-shaped positioning frame to clamp the wire harness, the two first V-shaped positioning frames are simultaneously driven to close towards each other through the cooperation of the Z-shaped guide frame and the transmission pulley.

[0009] Preferably, an L-shaped main shaft is rotatably connected inside the crimping machine housing. The top end face of the L-shaped main shaft has four guide grooves arranged in a cross shape along the radial direction. A guide rod is slidably connected in each guide groove. An arc-shaped inner ring plate is fixed at the top of the guide rod. When the four arc-shaped inner ring plates are closed, they form a complete cylindrical structure coaxial with the wire harness.

[0010] Preferably, the top of the L-shaped main shaft is coaxially rotatably connected to an adjustment plate. The adjustment plate has four adjustment slots that correspond to and are adapted to the guide slide rods. The adjustment slots and the guide slide rods are arranged at non-parallel inclination angles. A moving bevel gear is fixedly sleeved on the outer periphery of the adjustment plate. A fixed bevel gear that meshes with the moving bevel gear is fixed inside the pressing machine housing. The L-shaped main shaft is driven to rotate by a feeding motor fixed inside the pressing machine housing.

[0011] Preferably, the inside of the crimping machine housing is also provided with a waterproof plug feeding mechanism, which includes a first conveyor belt, a second electric push rod, a U-shaped feeding slide rail and a third electric push rod; The U-shaped feeding slide rail is located directly above the arc-shaped inner ring plate after it is deflected upwards. The second electric push rod is used to push the waterproof plug conveyed by the first conveyor belt into the U-shaped feeding slide rail. The third electric push rod is used to push the waterproof plug inside the U-shaped feeding slide rail to be sleeved on the outer periphery of the arc-shaped inner ring plate after it is folded up.

[0012] Preferably, a pair of symmetrically arranged centering rods are rotatably connected inside the crimping machine housing. A transmission rod passes through the top of the centering rod, and a transmission slider is rotatably connected to one end of the transmission rod. The transmission slider is slidably sleeved on the mutually perpendicular X-axis rod and Z-axis rod. The X-axis rod is fixedly connected to the crimping machine housing, and the V-shaped palm frame is fixed to the top of the transmission slider.

[0013] Preferably, a power spring is sleeved on the outer periphery of the transmission rod, and the power spring is disposed between the centering rod and the transmission slider; The centering rod has a driven bevel gear fixed at its bottom. A worm gear is rotatably connected inside the crimping machine housing. Two driving bevel gears that mesh with the driven bevel gear are symmetrically fixed at the shaft end of the worm gear. A worm that meshes with the worm gear is also rotatably connected inside the crimping machine housing. The worm is driven to rotate by a power motor fixed inside the crimping machine housing.

[0014] Preferably, the wire stripping assembly further includes a stripping slider, a fourth electric push rod, and a fifth electric push rod; The output end of the fourth electric push rod is fixedly connected to the stripping slider, and the fifth electric push rod is fixedly installed on the top of the stripping slider. The output end of the fifth electric push rod is fixedly connected to the gate. The switch is located on the side of the first V-shaped positioning frame away from the waterproof plug; The side wall of the crimping machine housing is also provided with a second process port, and a terminal crimping assembly and a terminal feeding mechanism are provided inside the crimping machine housing at the position corresponding to the second process port. The L-shaped spindle has a fixed bevel gear at its shaft end and is fixedly connected to an L-shaped feeding rod. An electric gripper is provided at the end of the L-shaped feeding rod. The terminal feeding mechanism includes a second conveyor belt, which is used to provide terminals to the electric gripper. The terminal crimping assembly includes a pair of V-shaped crimping blocks arranged opposite each other. The ends of the two V-shaped crimping blocks are respectively fixed with mutually meshing transmission racks. A transmission gear that meshes synchronously with the two transmission racks is rotatably connected inside the crimping machine housing. A hydraulic rod is fixed inside the crimping machine housing, and the output end of the hydraulic rod is fixedly connected to one of the V-shaped crimping blocks. While the L-shaped spindle drives the arc-shaped inner ring plate to deflect up and down, it simultaneously drives the L-shaped feeding rod to deflect up and down, realizing the synchronous driving of waterproof plug feeding and terminal feeding.

[0015] A semi-automatic terminal crimping method, preferably, includes the following steps: S1: Insert the pre-cut wire harness through the first process port into the crimping machine housing, and clamp the end of the wire harness by the first V-shaped positioning frame of the wire harness clamping mechanism. S2: The waterproof plug is held by the V-shaped palm clamp of the waterproof plug assembly and pushed along the axial direction of the wiring harness; S3: During the pushing process, the V-shaped transmission frame and the abutting rod abut against each other, causing the first V-shaped positioning frame to move along the T-shaped slide bar, so that the waterproof plug passes through the first V-shaped positioning frame and reaches the preset position; S4: The V-shaped transmission frame disengages from the contact rod, and the return spring drives the first V-shaped positioning frame to return and close, forming an axial limit on the waterproof plug, while physically isolating the waterproof plug from the switch of the wire stripping assembly; S5: The insulation at the end of the wire harness is cut and peeled off by the switch. During the cutting process, the waterproof plug is isolated outside the switch by the first V-shaped positioning frame. S6: After crimping the terminals at the ends of the wire harness, the finished product is removed manually.

[0016] The beneficial effects of this invention are: 1. This invention uses a V-shaped transmission frame at the end of the V-shaped hand frame to form a linkage with the abutment rod on the first V-shaped positioning frame. During the pushing process of the waterproof plug, the positioning frame is driven to move out of position, ensuring smooth installation of the waterproof plug. After the waterproof plug reaches the preset position, only the abutment constraint on the positioning frame is released. There is no need to completely remove the installation mechanism. The first V-shaped positioning frame is automatically reset and closed by the return spring. While reserving complete operating space for the wire stripping and crimping processes, it forms a continuous rigid axial limit on the waterproof plug, effectively improving the problems of waterproof plug rebound displacement and edge skew, and avoiding the situation where the switch cuts and damages the waterproof plug.

[0017] 2. The waterproof plug installation, wire harness clamping, and limiting isolation actions of the present invention are all achieved through a purely mechanical structure to realize strong correlation and timing linkage, without the need for multiple independent drive units to control them separately, thus reducing the problems of electrical control signal delay and action timing misalignment.

[0018] 3. The core limiting and isolation structure of this invention does not require an additional drive unit. It can complete the entire process of yielding, limiting, and isolation simultaneously by relying on the insertion action itself. The equipment structure is simple and easy to maintain. At the same time, through the self-adaptive centering structure of the V-shaped positioning frame, it can be compatible with the processing requirements of wire harnesses of different diameters and waterproof plugs of different specifications, without the need for frequent tooling changes, and has strong adaptability. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, for those skilled in the art, other drawings can be obtained based on these drawings without creative effort. Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is a schematic diagram of the overall internal structure of the crimping machine housing in this invention; Figure 3 This is a schematic diagram showing the installation positions of the wire harness clamping mechanism and the V-shaped palm support in this invention; Figure 4 This is a schematic diagram of the connection relationship between the X-axis rod and the Z-axis rod in this invention; Figure 5 This is a schematic diagram showing the installation positions of the second V-shaped positioning frame and the third V-shaped positioning frame in this invention; Figure 6 This is a schematic diagram of the overall structure of the first V-shaped positioning frame in this invention; Figure 7 This is a schematic diagram of the overall structure of the guillotine in this invention; Figure 8 This is a schematic diagram showing the connection relationship between the L-shaped main shaft and the L-shaped feeding rod in this invention; Figure 9 This is an exploded view of the connection relationship between the guide slide rod and the guide slide groove in this invention; Figure 10 This is a schematic diagram of the overall structure of the V-shaped crimping block in this invention.

[0020] The attached figures are labeled as follows: 1. Crimping machine housing; 2. First process port; 3. First V-shaped positioning frame; 4. T-shaped slide rod; 5. U-shaped mounting frame; 6. Return spring; 7. V-shaped palm support; 8. V-shaped transmission frame; 9. Contact rod; 10. Knife switch; 11. First electric push rod; 12. Second V-shaped positioning frame; 13. Third V-shaped positioning frame; 14. Z-shaped guide frame; 15. Transmission pulley; 16. L-shaped main shaft; 17. Guide groove; 18. Guide slide rod; 19. Arc-shaped inner ring plate; 20. Adjusting disc; 21. Adjusting through groove; 22. Moving bevel gear; 23. Fixed bevel gear; 24. Feeding motor; 25. Fixed... 26. Core rod; 27. Transmission rod; 28. Transmission slider; 29. ​​X-axis rod; 20. Z-axis rod; 31. Power spring; 32. Driven bevel gear; 33. Worm gear; 34. Driven bevel gear; 35. Worm; 36. Power motor; 37. Unloading slider; 38. Fourth electric push rod; 39. Fifth electric push rod; 40. V-shaped pressing block; 41. Transmission rack; 42. Transmission gear; 43. Hydraulic rod; 44. First conveyor belt; 45. Second electric push rod; 46. U-shaped feeding slide rail; 47. Third electric push rod; 48. Second process port; 49. L-shaped feeding rod; 50. Electric gripper; 61. Second conveyor belt. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] A semi-automatic terminal crimping device and method are mainly applied in the field of high-end waterproof wire harness processing equipment. The high-performance terminals used in this field are all based on advanced non-ferrous metal material systems and manufactured using novel electrical contact precious metal material manufacturing technology. This adapts to the automated, high-precision, and damage-free processing requirements of such high-end waterproof wire harnesses under flexible industrial production models. This invention utilizes a single power source for co-drive, linking a dual-point coaxial centering clamping mechanism, an integrated linkage assembly for waterproof plug insertion, clearance, and limiting, and a rigid physical barrier anti-cutting mechanism to solve the problems of traditional semi-automatic terminal crimping equipment. The existing technical problems include timing misalignment of multiple independent power sources, springback displacement of push-rod type plug insertion, damage to waterproof plugs during wire stripping, easy scratching of precious metal electrical contact layers, high risk of finished product sealing failure, and low processing energy efficiency. By combining pure mechanical rigid linkage with adaptive centering adjustment throughout the entire process, automated continuous production is achieved, waterproof plug positioning and processing actions are strongly synchronized, sealing structure is protected without damage, and precious metal electrical contact layers are processed without scratching. This meets the core usage requirements of high-reliability production, precise quality control of finished products, reduced raw material loss, and optimized processing energy efficiency in the fields of high-end electrical connections and energy-saving electrical accessories.

[0023] like Figures 1-10 As shown, it includes a crimping machine housing 1, and the side wall of the crimping machine housing 1 is provided with a first process port 2 for inserting wire harnesses. The crimping machine housing 1 is provided with a wire harness clamping mechanism, a waterproof plug insertion assembly, and a wire stripping assembly. The wire stripping assembly includes a knife 10 for cutting the insulation of the wire harness. The wire harness clamping mechanism includes a pair of first V-shaped positioning frames 3 arranged vertically opposite each other. One end of the first V-shaped positioning frame 3 is fixed with a T-shaped slide rod 4. The T-shaped slide rod 4 is slidably connected to the U-shaped mounting frame 5. A return spring 6 is sleeved on the outer periphery of the T-shaped slide rod 4. The two ends of the return spring 6 abut against the first V-shaped positioning frame 3 and the U-shaped mounting frame 5 respectively. The waterproof plug installation assembly includes a V-shaped palm frame 7 that can reciprocate along the axial direction of the wire harness. A V-shaped transmission frame 8 is fixed to the end of the V-shaped palm frame 7. A first V-shaped positioning frame 3 is rotatably connected to an abutment rod 9 that is adapted to the V-shaped transmission frame 8 at one end facing the V-shaped transmission frame 8. When the V-shaped palm frame 7 pushes the waterproof plug to move along the axial direction of the wire harness, the first V-shaped positioning frame 3 is moved along the guiding direction of the T-shaped slide rod 4 by the contacting cooperation between the V-shaped transmission frame 8 and the contact rod 9, so that the waterproof plug passes through the area between the two first V-shaped positioning frames 3. After the waterproof plug moves to the preset position, the V-shaped transmission frame 8 disengages from the contact rod 9, and the return spring 6 rebounds to drive the first V-shaped positioning frame 3 to reset and close, forming a clamp on the end of the wire harness while axially limiting the waterproof plug and physically isolating the waterproof plug from the switch 10. The wire harness clamping mechanism also includes a first electric push rod 11, a second V-shaped positioning frame 12, and a third V-shaped positioning frame 13; The second V-shaped positioning frame 12 is fixed to one end of the inner side of the first process port 2, and the third V-shaped positioning frame 13 is slidably disposed at the other end of the inner side of the first process port 2. The second V-shaped positioning frame 12 and the third V-shaped positioning frame 13 are arranged opposite each other on the left and right. The output end of the first electric push rod 11 is fixedly connected to the third V-shaped positioning frame 13 and is used to drive the third V-shaped positioning frame 13 to move closer to the second V-shaped positioning frame 12 to form a centering clamp on the middle section of the wire harness. Furthermore, the output end of the first electric actuator 11 is symmetrically fixed with two opposing Z-shaped guide frames 14, and a transmission pulley 15 is rotatably connected to one side of the U-shaped mounting bracket 5. The transmission pulley 15 is slidably embedded inside the Z-shaped guide frame 14. While the first electric actuator 11 drives the third V-shaped positioning frame 13 to clamp the wire harness, it simultaneously drives the two first V-shaped positioning frames 3 to close towards each other through the cooperation of the Z-shaped guide frame 14 and the transmission pulley 15. Furthermore, an L-shaped main shaft 16 is rotatably connected inside the crimping machine housing 1. The top end face of the L-shaped main shaft 16 is radially provided with four guide grooves 17 arranged in a cross shape. Each guide groove 17 is slidably connected with a guide rod 18. An arc-shaped inner ring plate 19 is fixed to the top of the guide rod 18. When the four arc-shaped inner ring plates 19 are closed, they form a complete cylindrical structure coaxial with the wire harness. Furthermore, an adjustment plate 20 is coaxially rotatably connected to the top of the L-shaped main shaft 16. The adjustment plate 20 has four adjustment slots 21 that correspond to and are adapted to the guide slide rods 18. The adjustment slots 21 and the guide slide rods 17 are arranged at non-parallel inclination angles. A moving bevel gear 22 is fixedly sleeved on the outer periphery of the adjustment plate 20. A fixed bevel gear 23 that meshes with the moving bevel gear 22 is fixed inside the pressing machine housing 1. The L-shaped main shaft 16 is driven to rotate by a feeding motor 24 fixed inside the pressing machine housing 1. Furthermore, the inside of the crimping machine housing 1 is also equipped with a waterproof plug feeding mechanism, which includes a first conveyor belt 43, a second electric push rod 44, a U-shaped feeding slide rail 45 and a third electric push rod 46. The U-shaped feeding slide rail 45 is located directly above the arc-shaped inner ring plate 19 after it is deflected upward. The second electric push rod 44 is used to push the waterproof plug conveyed by the first conveyor belt 43 into the U-shaped feeding slide rail 45. The third electric push rod 46 is used to push the waterproof plug in the U-shaped feeding slide rail 45 to be sleeved on the outer periphery of the arc-shaped inner ring plate 19 after it is folded up. Furthermore, a pair of symmetrically arranged centering rods 25 are rotatably connected inside the crimping machine housing 1. A transmission rod 26 passes through the top of the centering rod 25. A transmission slider 27 is rotatably connected to one end of the transmission rod 26. The transmission slider 27 is slidably sleeved on the mutually perpendicular X-axis rod 28 and Z-axis rod 29. The X-axis rod 28 is fixedly connected to the crimping machine housing 1. The V-shaped palm frame 7 is fixed to the top of the transmission slider 27. Furthermore, a power spring 30 is sleeved on the outer periphery of the transmission rod 26, and the power spring 30 is disposed between the centering rod 25 and the transmission slider 27; A driven bevel gear 31 is fixed at the bottom of the centering rod 25. A worm gear 32 is rotatably connected inside the crimping machine housing 1. Two driving bevel gears 33 that mesh with the driven bevel gear 31 are symmetrically fixed at the shaft end of the worm gear 32. A worm 34 that meshes with the worm gear 32 is also rotatably connected inside the crimping machine housing 1. The worm 34 is driven to rotate by a power motor 35 fixed inside the crimping machine housing 1. Furthermore, the wire stripping assembly also includes a stripping slider 36, a fourth electric actuator 37, and a fifth electric actuator 38; The output end of the fourth electric actuator 37 is fixedly connected to the stripper slider 36, and the fifth electric actuator 38 is fixedly installed on the top of the stripper slider 36. The output end of the fifth electric actuator 38 is fixedly connected to the gate 10. The switch 10 is located on the side of the first V-shaped positioning frame 3 away from the waterproof plug; The side wall of the crimping machine housing 1 is also provided with a second process port 47, and a terminal crimping assembly and a terminal feeding mechanism are provided inside the crimping machine housing 1 at the position corresponding to the second process port 47. The shaft end of the L-shaped main shaft 16 passes through the fixed bevel gear 23 and is fixedly connected to the L-shaped feeding rod 48. The end of the L-shaped feeding rod 48 is provided with an electric gripper 49. The terminal feeding mechanism includes a second conveyor belt 50, which is used to provide terminals to the electric gripper 49. The terminal crimping assembly includes a pair of V-shaped crimping blocks 39 arranged opposite each other. The ends of the two V-shaped crimping blocks 39 are respectively fixed with mutually meshing transmission racks 40. The crimping machine housing 1 is rotatably connected with a transmission gear 41 that meshes synchronously with the two transmission racks 40. The crimping machine housing 1 is fixed with a hydraulic rod 42. The output end of the hydraulic rod 42 is fixedly connected to one of the V-shaped crimping blocks 39. While the L-shaped spindle 16 drives the arc-shaped inner ring plate 19 to deflect up and down, it simultaneously drives the L-shaped feeding rod 48 to deflect up and down, realizing the synchronous driving of waterproof plug feeding and terminal feeding.

[0024] When in use, firstly, the pre-cut wire harness is manually inserted into the equipment through the first process port 2 of the crimping machine box 1. After the wire harness is inserted, it will be positioned between the middle positioning area and the end positioning area. At this time, the first electric push rod 11 is activated, which drives the third V-shaped positioning frame 13 to move closer to the fixed second V-shaped positioning frame 12. The middle section of the wire harness is first centered and clamped to prevent the wire harness from drooping or tilting due to its length and weight. At the same time, the moving end of the first electric push rod 11 will drive the Z-shaped guide frame 14 to move synchronously. Through the guiding cooperation between the Z-shaped guide frame 14 and the transmission pulley 15, the U-shaped mounting bracket 5 will be pulled to move, so that the upper and lower sets of first V-shaped positioning brackets 3 will close synchronously, and the end of the wire harness will be clamped twice to achieve coaxial positioning of the wire harness throughout the entire process, providing a stable reference for the subsequent installation of waterproof plugs. The feeding and diameter expansion of the waterproof plug are completed by the L-shaped main shaft 16 in conjunction with the feeding motor 24: First, the feeding motor 24 is started to drive the L-shaped main shaft 16 to rotate. The L-shaped main shaft 16 drives the arc-shaped inner ring plate 19 to deflect upward to directly below the U-shaped feeding slide rail 45. At this time, the moving bevel gear 22 on the L-shaped main shaft 16 meshes with the fixed bevel gear 23 fixed in the pressing machine box 1 and rotates. The moving bevel gear 22 drives the adjusting plate 20 to rotate. The adjusting groove 21 on the adjusting plate 20 deflects alternately with the guide slide groove 17 of the L-shaped main shaft 16, pushing the guide slide rod 18 to move along the guide slide groove 17, so that the four arc-shaped inner ring plates 19 perform a closing movement, and finally close together to form a complete cylindrical structure. Then the second electric push rod 44 is activated, pushing the waterproof plug conveyed by the output end of the first conveyor belt 43 into the U-shaped feeding slide rail 45. The third electric push rod 46 is then activated, pushing the waterproof plug in the U-shaped feeding slide rail 45 downward, so that the waterproof plug is directly fitted onto the outer periphery of the four arc-shaped inner ring pieces 19 after they are closed, thus completing the automatic feeding of the waterproof plug. After the waterproof plug is loaded, it enters the diameter expansion and wire fitting process: the loading motor 24 is reverse-started to drive the L-shaped main shaft 16 to rotate, causing the arc-shaped inner ring plate 19 to deflect downwards to the side facing the first V-shaped positioning frame 3; at the same time as the L-shaped main shaft 16 rotates in the reverse direction, the moving bevel gear 22 and the fixed bevel gear 23 mesh in the opposite direction, driving the adjusting plate 20 to rotate synchronously, and the adjusting through groove 21 and the guide slide groove 17 deflect alternately again, pushing the guide slide rod 18 to drive the four arc-shaped inner ring plates 19 to expand away from each other, thus expanding the inner diameter of the waterproof plug from the inside. At this time, the end of the wire harness is manually pulled through between the two first V-shaped positioning frames 3. Because the waterproof plug has been expanded, the end of the wire harness can be smoothly inserted between the four arc-shaped inner ring plates 19, completely avoiding hard contact between the waterproof plug and the end of the wire harness; when the L-shaped main shaft 16 drives the arc-shaped inner ring plate 19 to rotate upwards, relying on the flexibility of the wire harness itself, the wire harness will automatically detach from the arc-shaped inner ring plate 19, and the waterproof plug will remain and be fitted around the outer periphery of the wire harness; After the diameter expansion is completed, the power motor 35 starts, and through the transmission of the worm gear 34, worm wheel 32 and two sets of bevel gears, it drives the centering rod 25 and the transmission rod 26 to move, causing the transmission slider 27 to move along the X-axis rod 28 and Z-axis rod 29 in a regular rectangular trajectory, which in turn drives the V-shaped palm holder 7 to clamp the waterproof plug and push it forward along the wire harness axis. During the pushing process, the V-shaped transmission frame 8 at the front end of the V-shaped palm holder 7 will contact and push the abutment rod 9 on the first V-shaped positioning frame 3, forcing the first V-shaped positioning frame 3 to move outward along the T-shaped slide rod 4, making room for the waterproof plug to pass through, and ensuring that the waterproof plug can pass smoothly through the first V-shaped positioning frame 3 to reach the preset processing position; Once the waterproof plug has completely passed through and reached the designated position, the V-shaped transmission frame 8 moves away from the contact rod 9, releasing the contact limiting relationship. The return spring 6 on the T-shaped slide rod 4 immediately rebounds, pushing the first V-shaped positioning frame 3 to quickly return and close. At this time, the first V-shaped positioning frame 3, on the one hand, re-clamps the end of the wire harness, and on the other hand, it blocks the waterproof plug and the switch 10, forming an axial limit on the waterproof plug and physically separating the two. Then the wire stripping assembly starts working. The fifth electric push rod 38 drives the upper and lower sets of switches 10 to close, cutting the insulation at the end of the wire harness. Due to the obstruction of the first V-shaped positioning frame 3, the working range of the switches 10 will not touch the waterproof plug at all. After the cutting is completed, the fourth electric push rod 37 drives the stripping slider 36 to move axially, peeling the cut insulation from the wire harness and taking it out of the work station. Then the wire harness is completely pulled out from the first process port 2 by manual labor, completing the entire processing flow of the first work station. Finally, the stripped wire harness end is manually passed through the second process port 47 and extended between the two V-shaped crimping blocks 39. At the same time, the feeding motor 24 drives the L-shaped main shaft 16 to rotate the arc-shaped inner ring plate 19 upward to feed the next waterproof plug, and simultaneously drives the L-shaped feeding rod 48 to rotate upward to face the second process port 47. The electric gripper 49 at the end of the L-shaped feeding rod 48 has picked up the terminal on the second conveyor belt 50 when the L-shaped main shaft 16 rotates in the opposite direction. At this time, the electric gripper 49 accurately transfers the terminal between the two V-shaped crimping blocks 39, so that it fits against the wire harness end and the waterproof plug end face. Subsequently, the hydraulic rod 42 is activated, driving one of the V-shaped crimping blocks 39 to move. Through the synchronous meshing of the transmission rack 40 and the transmission gear 41, the upper and lower V-shaped crimping blocks 39 are driven to close towards each other, crimping and fixing the terminal to the outer periphery of the wire harness copper core and the waterproof plug, while simultaneously completing the electrical connection and sealing. After the crimping is completed, the hydraulic rod 42 is reset, the electric gripper 49 releases the terminal, and when the L-shaped spindle 16 rotates, it drives the L-shaped feeding rod 48 to deflect downward to above the second conveyor belt 50, picking up the next terminal. The finished wire harness is then manually removed from the second process port 47, completing a single complete processing cycle.

[0025] A semi-automatic terminal crimping method includes the following steps: S1: Insert the pre-cut wire harness through the first process port 2 into the crimping machine housing 1, and clamp the end of the wire harness by the first V-shaped positioning frame 3 of the wire harness clamping mechanism. S2: The waterproof plug is held by the V-shaped palm holder 7 of the waterproof plug installation assembly and pushed along the axial direction of the wiring harness; S3: During the pushing process, the V-shaped transmission frame 8 and the abutting rod 9 abut against each other, causing the first V-shaped positioning frame 3 to move along the T-shaped slide rod 4, so that the waterproof plug passes through the first V-shaped positioning frame 3 and reaches the preset position. S4: The V-shaped transmission frame 8 disengages from the contact rod 9, and the return spring 6 drives the first V-shaped positioning frame 3 to return and close, forming an axial limit on the waterproof plug, while physically isolating the waterproof plug from the switch 10 of the wire stripping assembly. S5: The insulation at the end of the wire harness is cut and peeled off by the switch 10. During the cutting process, the waterproof plug is isolated outside the switch 10 by the first V-shaped positioning frame 3. S6: After crimping the terminals at the ends of the wire harness, the finished product is removed manually.

[0026] The working principle of the semi-automatic terminal crimping device and method provided by this invention is as follows: First, the wire harness is manually inserted into the crimping machine box 1 through the first process port 2. Then, the first electric push rod 11 starts to output linear driving force, driving the third V-shaped positioning frame 13 to move horizontally towards the fixed second V-shaped positioning frame 12. Using the self-adaptive centering principle of the V-shaped structure, the middle section of the wire harness is clamped and fixed to prevent the wire harness from drooping and tilting due to its own weight. At the same time, the first electric actuator 11 drives the Z-shaped guide frame 14 to move synchronously. Through the curved guide groove of the Z-shaped guide frame 14 and the rolling cooperation of the transmission pulley 15, the horizontal linear motion is converted into vertical motion, which pulls the U-shaped mounting frame 5 to drive the first V-shaped positioning frame 3 to close vertically. Relying on the transmission principle of synchronous driving of the dual clamping station by a single power source, the coaxial centering clamping of the middle section and the end of the wire harness is realized, providing a precise positioning reference for subsequent processes. The feeding motor 24 drives the L-shaped main shaft 16 to rotate, deflecting the arc-shaped inner ring piece 19 to the feeding station. At the same time, the moving bevel gear 22 meshes with the fixed bevel gear 23, driving the adjusting plate 20 to rotate. Through the radial transmission principle of the inclined groove, the arc-shaped inner ring piece 19 is brought together into a cylinder, providing a support carrier for the installation of the waterproof plug. The second electric push rod 44, based on the linear drive principle, pushes the waterproof plug conveyed by the first conveyor belt 43 to the U-shaped feeding slide rail 45. The third electric push rod 46 continues to drive vertically, accurately installing the waterproof plug on the outer circumference of the arc-shaped inner ring piece 19, completing the automated feeding. The feeding motor 24 drives the L-shaped main shaft 16 to rotate in the opposite direction. The moving bevel gear 22 and the fixed bevel gear 23 mesh in the opposite direction. The arc-shaped inner ring plate 19 is radially expanded again through the principle of interlaced oblique groove transmission, which expands the inner diameter of the waterproof plug from the inside and eliminates assembly interference. At this time, the end of the wire harness can be smoothly inserted between the expanded arc-shaped inner ring plate 19, which completely avoids the hard collision between the waterproof plug and the end of the wire harness. When the arc-shaped inner ring plate 19 rotates in the future, the wire harness will detach from the inner ring due to its own flexibility, and the waterproof plug will be stably sleeved on the outer periphery of the wire harness, completing the undamaged wire sleeve. The power motor 35 drives the worm gear 34 to rotate. Based on the worm gear reduction and self-locking transmission principle, it drives the worm wheel 32 and the driving bevel gear 33 to rotate. The driving bevel gear 33 and the driven bevel gear 31 mesh and reverse direction, driving the centering rod 25 to drive the transmission rod 26 to swing. Under the two-dimensional guiding constraint of the X-axis rod 28 and the Z-axis rod 29, the transmission slider 27 drives the V-shaped palm frame 7 to move in a regular rectangular trajectory. The V-shaped palm frame 7 clamps the waterproof plug and pushes it along the axial direction of the wire harness. During the pushing process, the V-shaped transmission frame 8 and the contact rod 9 form a rolling contact. Relying on the principle of inclined plane pushing force conversion, the axial pushing force is converted into a vertical spreading force, which drives the first V-shaped positioning frame 3 to move vertically along the T-shaped slide rod 4. The compression return spring 6 generates elastic deformation, making way for the waterproof plug to pass through and ensuring that the waterproof plug passes smoothly through the clamping area. When the waterproof plug reaches the preset position, the V-shaped transmission frame 8 disengages from the contact rod 9 as it moves, and the pushing force disappears. The return spring 6 releases its elastic potential energy and, relying on the principle of elastic automatic reset, pushes the first V-shaped positioning frame 3 to quickly reset and close along the T-shaped slide rod 4. On the one hand, it re-centers and clamps the end of the wire harness, and on the other hand, the end face of the first V-shaped positioning frame 3 forms an axial rigid limit on the waterproof plug, which counteracts the rebound force accumulated by the waterproof plug due to compression deformation and prevents rebound displacement. At the same time, the first V-shaped positioning frame 3 is located between the waterproof plug and the switch 10. Relying on the principle of rigid barrier of mechanical structure, it forms a physical isolation layer, which structurally limits the working range of the switch 10 and completely avoids cutting the waterproof plug. The fifth electric actuator 38 outputs vertical driving force to drive the sluice gate 10 to close in opposite directions, cutting the insulation at the end of the wire harness based on the double-blade ring cutting principle; after cutting, the fourth electric actuator 37 outputs axial driving force to drive the stripping slider 36 to move the sluice gate 10 along the axial direction of the wire harness, peeling off the cut insulation from the wire harness and taking it out of the work station based on the axial drag stripping principle, avoiding wire insulation residue jamming; Since the L-shaped main shaft 16 is connected to both the arc-shaped inner ring plate 19 and the L-shaped feeding rod 48 at the shaft end, when the L-shaped main shaft 16 rotates, it can simultaneously realize the feeding of the waterproof plug of the arc-shaped inner ring plate 19 and the feeding of the terminal of the L-shaped feeding rod 48; the two independent work stations are divided by the first process port 2 and the second process port 47. When the wire harness end that has been stripped is manually passed through the second process port 47 and extended between the two V-shaped crimping blocks 39, the electric gripper 49 at the end of the L-shaped feeding rod 48 has picked up the terminal on the second conveyor belt 50 when the L-shaped main shaft 16 rotates in the opposite direction, and transferred it between the two V-shaped crimping blocks 39 to fit with the wire harness end and the waterproof plug end face; Subsequently, the hydraulic rod 42 outputs a vertical crimping force, driving one of the V-shaped crimping blocks 39 to move. This crimping block drives the transmission rack 40 to move, and relying on the synchronous meshing transmission principle of the gear rack, it drives the other V-shaped crimping block 39 to synchronously close towards each other, so that the two sets of crimping blocks are subjected to uniform force and move synchronously, completing the electrical crimping of the terminal and the copper core of the wire harness, as well as the sealing and tightening of the terminal to the waterproof plug, ensuring crimping accuracy and waterproof sealing effect; after the crimping is completed, all components are reset in sequence, completing a single processing cycle.

[0027] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed invention.

Claims

1. A semi-automatic terminal crimping device, characterized in that: The crimping machine includes a crimping machine housing (1), the side wall of which is provided with a first process port (2) for inserting wire harnesses. Inside the crimping machine housing (1) are a wire harness clamping mechanism, a waterproof plug insertion assembly, and a wire stripping assembly. The wire stripping assembly includes a knife (10) for cutting the insulation of the wire harness. The wire harness clamping mechanism includes a pair of first V-shaped positioning frames (3) arranged opposite each other. One end of the first V-shaped positioning frame (3) is fixed with a T-shaped slide rod (4). The T-shaped slide rod (4) is slidably connected to the U-shaped mounting frame (5). A return spring (6) is sleeved on the outer periphery of the T-shaped slide rod (4). The two ends of the return spring (6) abut against the first V-shaped positioning frame (3) and the U-shaped mounting frame (5) respectively. The waterproof plug installation assembly includes a V-shaped palm frame (7) that can reciprocate along the axial direction of the wire harness. A V-shaped transmission frame (8) is fixed at the end of the V-shaped palm frame (7). A first V-shaped positioning frame (3) is rotatably connected to an abutment rod (9) that is adapted to the V-shaped transmission frame (8) at one end facing the V-shaped transmission frame (8). When the V-shaped hand frame (7) pushes the waterproof plug, the V-shaped transmission frame (8) abuts against the abutting rod (9), causing the first V-shaped positioning frame (3) to move along the T-shaped slide rod (4) to allow the waterproof plug to pass through; after the waterproof plug is in place, the V-shaped transmission frame (8) disengages from the abutting rod (9), and the reset spring (6) drives the first V-shaped positioning frame (3) to reset and close, so as to clamp the end of the wire harness, limit the axial movement of the waterproof plug, and physically isolate the waterproof plug from the switch (10).

2. The semi-automatic terminal crimping equipment according to claim 1, characterized in that: The wire harness clamping mechanism also includes a first electric push rod (11), a second V-shaped positioning frame (12), and a third V-shaped positioning frame (13). The second V-shaped positioning frame (12) is fixed to one end of the inner side of the first process port (2), and the third V-shaped positioning frame (13) is slidably disposed at the other end of the inner side of the first process port (2). The second V-shaped positioning frame (12) and the third V-shaped positioning frame (13) are arranged opposite each other on the left and right. The output end of the first electric push rod (11) is fixedly connected to the third V-shaped positioning frame (13) to drive the third V-shaped positioning frame (13) to move closer to the second V-shaped positioning frame (12) and form a centering clamp on the middle section of the wire harness.

3. The semi-automatic terminal crimping equipment according to claim 2, characterized in that: The output end of the first electric actuator (11) is also symmetrically fixed with two opposing Z-shaped guide frames (14), and a transmission pulley (15) is rotatably connected to one side of the U-shaped mounting bracket (5). The transmission pulley (15) is slidably embedded in the inside of the Z-shaped guide frame (14). While the first electric actuator (11) drives the third V-shaped positioning frame (13) to clamp the wire harness, it simultaneously drives the two first V-shaped positioning frames (3) to close towards each other through the cooperation of the Z-shaped guide frame (14) and the transmission pulley (15).

4. The semi-automatic terminal crimping equipment according to claim 1, characterized in that: The crimping machine housing (1) is also rotatably connected to an L-shaped main shaft (16). The top end face of the L-shaped main shaft (16) is radially provided with four guide grooves (17) arranged in a cross shape. Each guide groove (17) is slidably connected to a guide rod (18). The top of the guide rod (18) is fixed with an arc-shaped inner ring plate (19). When the four arc-shaped inner ring plates (19) are closed, they form a complete cylindrical structure coaxial with the wire harness.

5. The semi-automatic terminal crimping equipment according to claim 4, characterized in that: The top of the L-shaped main shaft (16) is coaxially rotatably connected to an adjustment plate (20). The adjustment plate (20) has four adjustment slots (21) that correspond to and are adapted to the guide slide rod (18). The adjustment slots (21) and the guide slide rod (17) are arranged at non-parallel inclination angles. The outer periphery of the adjustment plate (20) is fixedly fitted with a moving bevel gear (22). The inside of the pressing machine box (1) is fixed with a fixed bevel gear (23) that meshes with the moving bevel gear (22). The L-shaped main shaft (16) is driven to rotate by a feeding motor (24) fixed inside the pressing machine box (1).

6. The semi-automatic terminal crimping equipment according to claim 5, characterized in that: The crimping machine housing (1) is also equipped with a waterproof plug feeding mechanism, which includes a first conveyor belt (43), a second electric push rod (44), a U-shaped feeding slide rail (45) and a third electric push rod (46). The U-shaped feeding slide rail (45) is located directly above the arc-shaped inner ring plate (19) after it is deflected upwards. The second electric push rod (44) is used to push the waterproof plug conveyed by the first conveyor belt (43) into the U-shaped feeding slide rail (45). The third electric push rod (46) is used to push the waterproof plug in the U-shaped feeding slide rail (45) to be sleeved on the outer periphery of the arc-shaped inner ring plate (19) after it is folded up.

7. The semi-automatic terminal crimping equipment according to claim 1, characterized in that: The crimping machine housing (1) is rotatably connected to a pair of symmetrically arranged centering rods (25). A transmission rod (26) is passed through the top of the centering rod (25). A transmission slider (27) is rotatably connected to one end of the transmission rod (26). The transmission slider (27) is slidably sleeved on the mutually perpendicular X-axis rod (28) and Z-axis rod (29). The X-axis rod (28) is fixedly connected to the crimping machine housing (1). The V-shaped palm frame (7) is fixed to the top of the transmission slider (27).

8. The semi-automatic terminal crimping equipment according to claim 7, characterized in that: A power spring (30) is sleeved on the outer periphery of the transmission rod (26), and the power spring (30) is located between the centering rod (25) and the transmission slider (27); The bottom of the centering rod (25) is fixed with a driven bevel gear (31), and a worm gear (32) is rotatably connected inside the crimping machine housing (1). Two driving bevel gears (33) that mesh with the driven bevel gear (31) are symmetrically fixed at the shaft end of the worm gear (32). A worm (34) that meshes with the worm gear (32) is also rotatably connected inside the crimping machine housing (1). The worm (34) is driven to rotate by a power motor (35) fixed inside the crimping machine housing (1).

9. The semi-automatic terminal crimping equipment according to claim 1, characterized in that: The wire stripping assembly also includes a stripping slider (36), a fourth electric actuator (37), and a fifth electric actuator (38). The output end of the fourth electric push rod (37) is fixedly connected to the stripping slider (36), and the fifth electric push rod (38) is fixedly installed on the top of the stripping slider (36). The output end of the fifth electric push rod (38) is fixedly connected to the guillotine (10). The guillotine (10) is located on the side of the first V-shaped positioning frame (3) away from the waterproof plug; The side wall of the crimping machine housing (1) is also provided with a second process port (47), and a terminal crimping assembly and a terminal feeding mechanism are provided inside the crimping machine housing (1) at the position corresponding to the second process port (47); The shaft end of the L-shaped main shaft (16) passes through the fixed bevel gear (23) and is fixedly connected to the L-shaped feeding rod (48). The end of the L-shaped feeding rod (48) is provided with an electric gripper (49). The terminal feeding mechanism includes a second conveyor belt (50), which is used to provide terminals to the electric gripper (49). The terminal crimping assembly includes a pair of V-shaped crimping blocks (39) arranged opposite each other. The ends of the two V-shaped crimping blocks (39) are respectively fixed with mutually meshing transmission racks (40). The crimping machine housing (1) is rotatably connected with a transmission gear (41) that meshes synchronously with the two transmission racks (40). The crimping machine housing (1) is fixed with a hydraulic rod (42). The output end of the hydraulic rod (42) is fixedly connected to one of the V-shaped crimping blocks (39). While the L-shaped spindle (16) drives the arc-shaped inner ring plate (19) to deflect up and down, it simultaneously drives the L-shaped feeding rod (48) to deflect up and down, realizing the synchronous driving of waterproof plug feeding and terminal feeding.

10. A semi-automatic terminal crimping method, implemented based on the semi-automatic terminal crimping equipment according to any one of claims 1-9, characterized in that, Includes the following steps: S1: Pass the pre-cut wire harness through the first process port (2) and insert it into the crimping machine box (1). The wire harness end is clamped by the first V-shaped positioning frame (3) of the wire harness clamping mechanism. S2: The waterproof plug is held by the V-shaped palm frame (7) of the waterproof plug through the assembly and pushed along the axial direction of the wire harness; S3: During the pushing process, the V-shaped transmission frame (8) and the contact rod (9) engage in contact, causing the first V-shaped positioning frame (3) to move along the T-shaped slide rod (4) so ​​that the waterproof plug passes through the first V-shaped positioning frame (3) and reaches the preset position; S4: The V-shaped transmission frame (8) disengages from the contact rod (9), and the return spring (6) drives the first V-shaped positioning frame (3) to return and close, forming an axial limit on the waterproof plug, and at the same time physically isolating the waterproof plug from the switch (10) of the stripping assembly. S5: The insulation at the end of the wire harness is cut and peeled off by the switch (10). During the cutting process, the waterproof plug is isolated outside the switch (10) by the first V-shaped positioning frame (3). S6: After crimping the terminals at the ends of the wire harness, the finished product is removed manually.

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