A harness terminal bulk insertion apparatus and method

Abstract

This invention discloses a batch insertion device and method for wire harness terminals. The device includes a housing feeding mechanism, a transferring mechanism, and a combing mechanism. The housing feeding mechanism is equipped with a vibrating feeding tray and a misalignment separation component. The platform of the misalignment separation component can slide vertically along the mounting frame, and the platform has a receiving groove inside. The transferring mechanism is equipped with a six-axis robotic arm, a force sensor, and grippers. The force sensor adjusts the clamping force in real time to accommodate the transfer of multiple housing models. The fixing component of the combing mechanism pre-fixes the wire harness terminals through a terminal clamping plate, and the moving component drives the combing clamping plate to move and separate messy wire harnesses. The various mechanisms work together to complete the integrated operation of automatic housing material transfer and wire harness terminal straightening and pre-processing. It is compatible with mixed production of multiple specifications of products, reduces tooling change-of-line downtime, optimizes terminal insertion alignment accuracy, reduces defects such as terminal bending and plating scratches, and effectively improves the assembly efficiency and finished product consistency of wire harness connectors.

Description

Technical Field

[0001] This invention relates to the field of electronic wire harness connector assembly technology, and in particular to a batch insertion device and method for wire harness terminals. Background Technology

[0002] In the manufacturing process of electrical products such as automotive electronics, industrial control equipment, and home appliance electrical control, electronic wire harness connectors are the core connecting components for circuit signal transmission and power connection. Conventional connectors are assembled from multiple sets of electronic wire harnesses, end wire harness terminals (PIN conductive pins), and insulating plastic shells. During the production process, multiple wire harness end PIN pins need to be aligned and pressed together and assembled into the preset pin slots inside the plastic shell of the same specification to complete the wire harness connector assembly.

[0003] Currently, the mainstream assembly processes in the industry are divided into two categories: manual assembly and simple fixed-tool semi-automatic assembly. Manual assembly relies on operators manually combing through individual pins and inserting them one by one into the pin slots of the plastic housing, resulting in extremely low work efficiency. Existing semi-automatic assembly tooling uses a fixed limiting structure to complete the initial positioning of the pins, which is suitable for the production of conventional batches of single-model plastic housings. However, the existing assembly structure and production process have many insurmountable technical defects in the case of batch assembly of multi-pin wire harnesses and co-production of multiple specifications of plastic housings.

[0004] Specifically, in the existing structure, the pins at the ends of multiple wire harnesses lack a unified and orderly positioning structure. The flexible arrangement of the wire harnesses results in a messy overall arrangement of the finished pins and large spacing deviations. During the shell assembly process, misaligned pins are prone to hard compression and structural interference with the plastic shell and adjacent pins, which can easily lead to defects such as pin bending, pin deformation, plating scratches, and pin spacing deviations. At the same time, it is impossible to achieve synchronous alignment and precise insertion of multiple pins, making it difficult to control the assembly pass rate and assembly consistency, and significantly increasing product rework costs. Meanwhile, the existing assembly tooling is a single-model, customized, fixed tooling for plastic shells. When the production line switches to different shapes... When producing sized plastic shell products, operators need to stop the machine to disassemble the original tooling fixtures, replace the entire set of positioning and limiting components, and readjust the tooling reference. Tooling changeover is cumbersome and time-consuming, resulting in extremely low production efficiency and significant losses due to production line downtime. Furthermore, due to the limitations of the custom-designed tooling structure, different models of plastic shells cannot share the same set of assembly tooling to complete the pin insertion operation. The production line cannot achieve simultaneous production of multiple models of connector plastic shells and multiple specifications of pin wire harnesses, resulting in extremely poor production flexibility. It is difficult to adapt to the current demand for flexible production of small batches, multiple batches, and multiple categories of wire harness connectors, leading to low overall production line equipment utilization and comprehensive production capacity. Summary of the Invention

[0005] Therefore, the technical problem to be solved by the present invention is to overcome the problems of poor pin regularity, difficulty in synchronous and accurate insertion, and inability to achieve flexible production of mixed lines in the prior art, and to provide a batch insertion device and method for wire harness terminals.

[0006] To solve the above-mentioned technical problems, the present invention provides a batch insertion device for wire harness terminals, comprising: a housing feeding mechanism, the housing feeding mechanism including a vibrating feeding plate and a misalignment separation component, wherein the housings to be assembled are fed through the vibrating feeding plate; the misalignment separation component including a mounting frame and a platform, the mounting frame being disposed at the component output end of the vibrating feeding plate, and the platform being slidably connected to the mounting frame in a vertical direction, and having an internal receiving groove for receiving a single housing; and a material transfer mechanism, the material transfer mechanism including a six-axis robotic arm, a force sensor, and a gripper, the six-axis robotic arm being disposed on one side of the misalignment separation component, and the gripper being disposed at the moving end of the six-axis robotic arm to grip the housing. The force sensor's detection end is connected to the gripper; the combing mechanism includes a combing frame, a fixing component, and a moving component. The combing frame is disposed on one side of the material transfer mechanism. The fixing component and the moving component are both disposed on the combing frame. The fixing component includes a fixing frame and a terminal clamping plate. The fixing frame is fixedly connected to one side of the combing frame, and the terminal to be assembled can be clamped and fixed in the terminal clamping plate. The moving component includes a moving module, a slide, and a combing clamp. The moving module is horizontally disposed on the combing frame. The slide is slidably connected to the moving module. The combing clamp is disposed on the slide to clamp the separating terminal connecting wire.

[0007] In one embodiment of the present invention, the housing feeding mechanism further includes a direct vibration feeding assembly, which is disposed between the vibrating feeding plate and the misalignment separation assembly. The direct vibration feeding assembly includes a base frame, a direct vibrator, and a transmission channel. The direct vibrator is disposed on the base frame, and the transmission channel is disposed at the power output end of the direct vibrator. The feed end of the transmission channel is connected to the vibrating feeding plate, and its discharge end is disposed towards the misalignment separation assembly for batch directional transmission of housings.

[0008] In one embodiment of the present invention, the direct vibration feeding assembly further includes a cover plate and a feeding detector. The feeding detector is disposed at the feed end of the transmission channel, and the detection end of the feeding detector is disposed facing the inside of the transmission channel. The cover plate is fastened to the top of the transmission channel.

[0009] In one embodiment of the present invention, the misalignment separation component further includes a lifting module, the lifting module including a lifting rail, a lifting driver, a lifting frame, and at least two lifting limit blocks. The lifting rail is disposed on the mounting frame and extends vertically. The lifting driver is disposed at one end of the lifting rail. The lifting frame is connected to the power output end of the lifting driver and slidably connected to the lifting rail. The platform is connected to the top of the lifting frame to move synchronously with the lifting frame. The two lifting limit blocks are respectively connected to the mounting frame and are spaced apart vertically. Each lifting limit block extends horizontally toward the lifting frame to limit the travel of the lifting frame.

[0010] In one embodiment of the present invention, the misalignment separation assembly further includes a first limiting module and a second limiting module. The first limiting module includes a first limiting driver and a first limiting member. The first limiting driver is disposed on the lifting frame and located at the end of the platform away from the vibrating feeding plate. The first limiting member is connected to the power output end of the first limiting driver and can extend into the receiving groove to limit the movement position of the housing in the length direction of the platform. The second limiting module includes a second limiting driver and a second limiting member. The second limiting driver is disposed on the mounting frame. The second limiting member is connected to the power output end of the second limiting driver and can pass through the clearance groove at the bottom of the platform to the limiting groove communicating with one side of the receiving groove in the width direction to limit the movement position of the housing in the width direction of the platform.

[0011] In one embodiment of the present invention, the material transfer mechanism includes an opening and closing driver connected to the power output end of the six-axis robotic arm, a force sensor connected to the opening and closing driver, and at least two grippers connected to the power output end of the opening and closing driver for relative opening and closing movement.

[0012] In one embodiment of the present invention, the gripper includes a connecting portion, an extension portion, and a contoured clamping portion. The connecting portion is detachably connected to the power output end of the opening and closing driver. The extension portion extends from the connecting portion in a direction away from the opening and closing driver. The contoured clamping portion is disposed at the free end of the extension portion and configured to match the shape of the outer surface of the housing to be assembled.

[0013] In one embodiment of the present invention, the moving component includes a rotary driver, a lead screw, and two transmission plates. The rotary driver is disposed on the top of the carriage. The lead screw extends vertically and one end is connected to the power output end of the rotary driver. Both transmission plates are connected to the lead screw via threaded sleeves disposed thereon, and the thread structures of the two threaded sleeves are arranged oppositely to drive the two transmission plates to move relative to each other. The comb clamps are respectively connected to the two transmission plates. The fixing component includes a clamping driver disposed on the fixing frame, and the two terminal clamping plates are respectively connected to the power output end of the clamping driver.

[0014] In one embodiment of the present invention, the wire harness terminal batch insertion equipment includes a control mechanism and multiple housing feeding mechanisms. The multiple housing feeding mechanisms respectively feed and transfer housings of different models. The multiple housing feeding mechanisms, the material transfer mechanism and the wire combing mechanism are respectively connected to the control mechanism.

[0015] This invention also provides a method for batch insertion of wire harness terminals, which uses the aforementioned batch insertion equipment for wire harness terminals. The method employs a material transfer mechanism to drive multiple wire harness terminals after combing for batch insertion and assembly. The material transfer mechanism uses a force sensor to adjust its clamping and transmission force in real time to accommodate different housings. The housing loading process includes: step S1, batch transfer of housings to be assembled using a vibrating loading tray; step S2, when the housing to be assembled moves to the platform of the misalignment separation component, driving the platform to rise to separate individual housings to be assembled; the terminal connection wire combing process includes: step a, placing the terminals to be assembled in a fixed component; step b, clamping and separating the terminal connection wires using a combing clamp in a moving component; step c, driving the combing clamp to move to comb the terminal connection wires.

[0016] The technical solution of the present invention has the following advantages compared with the prior art:

[0017] The wire harness terminal batch insertion equipment and method of this invention utilizes a housing feeding mechanism, a transferring mechanism, and a combing mechanism in coordinated operation. First, a vibrating feeding tray achieves continuous automated feeding of plastic housings. Then, a vertically lifting, staggered separation component platform separates individual housings one by one, preventing housing stacking and jamming, ensuring orderly and individual output. Next, a six-axis robotic arm equipped with a force sensor, along with grippers, precisely picks up the housings. The force sensor provides real-time feedback on the clamping force, preventing both excessive clamping force that could damage the plastic housing and insufficient clamping force. The design prevents the housing from slipping, improving the stability and protection of the housing during transport. At the same time, an independent combing mechanism is set up to pre-process multiple messy wire harness terminals. The terminal clamping plate of the fixed component first completes the positioning and clamping of the wire harness end terminals. Then, the moving module drives the slide and the combing plate to move horizontally. The toothed structure of the combing plate separates and combs multiple wire harnesses, effectively eliminating the problems of wire harness terminals tangling and misalignment interference. After being straightened, the terminals can maintain a uniform spacing and posture, which is convenient for subsequent synchronous and precise insertion with the plastic shell.

[0018] In this complete set of equipment, the various mechanisms work together to achieve automatic material distribution and transfer of housings and automatic sorting and arrangement of wire harness terminals in an integrated operation. There is no need for manual sorting of wire harnesses and housings, which greatly reduces the intensity of manual operation. At the same time, it can adapt to the assembly needs of different specifications of plastic housings and a large number of wire harness terminals, reduce downtime losses caused by frequent tooling changes, improve the flexibility of the production line, improve the terminal insertion and alignment accuracy, reduce the output of defective products such as terminal bending, plating scratches, and assembly misalignment, and significantly improve the overall assembly efficiency and finished product assembly consistency of wire harness connectors. Attached Figure Description

[0019] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0020] Figure 1 This is a three-dimensional structural schematic diagram of the wire harness terminal batch insertion equipment according to a preferred embodiment of the present invention;

[0021] Figure 2 yes Figure 1 A three-dimensional structural diagram of the housing feeding mechanism in the batch insertion equipment for wire harness terminals shown.

[0022] Figure 3 yes Figure 1 A three-dimensional structural diagram of the misalignment separation component in the batch insertion equipment for wire harness terminals shown.

[0023] Figure 4 yes Figure 1 The side view of the misalignment separation component in the batch insertion equipment for wire harness terminals shown;

[0024] Figure 5 yes Figure 2 Enlarged structural diagram at point A in the middle;

[0025] Figure 6 yes Figure 4 Enlarged structural diagram at point B;

[0026] Figure 7 yes Figure 1 A three-dimensional structural diagram of the platform in the batch insertion equipment for wire harness terminals is shown.

[0027] Figure 8 yes Figure 1 A three-dimensional structural diagram of part of the material transfer mechanism in the batch insertion equipment for wire harness terminals shown;

[0028] Figure 9 yes Figure 1 A three-dimensional structural diagram of the combing mechanism in the batch insertion equipment for wire harness terminals shown.

[0029] Figure 10 yes Figure 1 The side view of the combing mechanism in the batch insertion equipment for wire harness terminals shown;

[0030] Figure 11 yes Figure 1 The diagram shows a three-dimensional structural schematic of the fixing component in the batch insertion equipment for wire harness terminals.

[0031] Explanation of reference numerals in the accompanying drawings: 100, Housing feeding mechanism; 110, Vibrating feeding tray; 120, Straight vibration feeding assembly; 121, Straight vibrator; 122, Transmission channel; 123, Cover plate; 124, Base frame; 125, Feeding detector; 130, Misalignment separation assembly; 131, Mounting frame; 132, Lifting module; 1321, Lifting limit block; 1322, Lifting driver; 1323, Lifting rail; 1324, Lifting frame; 133, First limit module; 1331, First limit driver; 1332, First limit member; 134, Second limit module; 1341, Second limit driver; 1342, Second limit member; 135, Platform; 1351. Receiving groove; 1352. Limiting groove; 1353. Clearing groove; 200. Transfer mechanism; 210. Six-axis robotic arm; 220. Opening and closing actuator; 230. Force sensor; 240. Gripper; 241. Connecting part; 242. Extension part; 243. Contouring clamping part; 300. Combing mechanism; 310. Combing frame body; 320. Fixing component; 321. Fixing frame; 322. Terminal clamping plate; 323. Clamping actuator; 330. Moving component; 331. Moving module; 332. Slide; 333. Combing clamping plate; 334. Transmission plate; 3341. Threaded sleeve; 335. Transmission screw; 336. Rotary actuator; 400. Housing. Detailed Implementation

[0032] The present invention will be further described below with reference to the accompanying drawings and specific embodiments, so that those skilled in the art can better understand and implement the present invention. However, the embodiments described are not intended to limit the present invention.

[0033] Example 1: See Figures 1 to 11 As shown, this embodiment provides a batch insertion device for wire harness terminals, which includes: a housing feeding mechanism 100, which includes a vibrating feeding plate 110 and a misalignment separation component 130. The housing 400 to be assembled is fed through the vibrating feeding plate 110. The misalignment separation component 130 includes a mounting frame 131 and a platform 135. The mounting frame 131 is disposed at the component output end of the vibrating feeding plate 110, and the platform 135 is slidably connected to the mounting frame 131 in the vertical direction. It has an internal receiving groove 1351 for receiving a single housing 400; and a transfer mechanism 200, which includes a six-axis robotic arm 210, a force sensor 230, and a gripper 240. The six-axis robotic arm 210 is disposed on one side of the misalignment separation component 130, and the gripper 240 is disposed at the moving end of the six-axis robotic arm 210 to grip the housing 400. The force sensor 230... The detection end of 30 is connected to the gripper 240; the combing mechanism 300 includes a combing frame 310, a fixing component 320, and a moving component 330. The combing frame 310 is disposed on one side of the transfer mechanism 200. The fixing component 320 and the moving component 330 are both disposed on the combing frame 310. The fixing component 320 includes a fixing frame 321 and a terminal clamping plate 322. 321 is fixed to one side of the comb frame 310, and the terminal to be assembled can be clamped and fixed in the terminal clamping plate 322. The moving component 330 includes a moving module 331, a slide 332 and a comb clamping plate 333. The moving module 331 is horizontally arranged on the comb frame 310, the slide 332 is slidably connected to the moving module 331, and the comb clamping plate 333 is arranged on the slide 332 to clamp the separator terminal connecting wire.

[0034] In this embodiment, the shell feeding mechanism 100 serves as the automatic plastic shell feeding unit of the equipment. It completes the continuous directional conveying of large batches of plastic shells with the help of the vibrating feeding plate 110, replacing the manual continuous feeding operation and ensuring uninterrupted material supply in the assembly process. The misalignment separation component 130 matched with the output end of the vibrating feeding plate 110 can complete the sorting of individual shells 400. The platform 135, which can slide vertically along the mounting frame 131, receives and isolates individual plastic shells through lifting action, separating the stacked shells 400 one by one into the receiving tank 1351. This avoids the faults of multiple shells 400 squeezing each other and stacking and jamming from the source, so that the plastic shells are stably output to the picking station in an independent single state. This provides a regular and interference-free material state for the subsequent robotic arm to accurately grasp the shells 400 in one go, realizing fully automatic plastic shell feeding and eliminating the manual sorting and separation process of shells 400, improving the continuity of plastic shell feeding and the stability of output.

[0035] Furthermore, the housing feeding mechanism 100 also includes a direct vibration feeding assembly 120, which is disposed between the vibrating feeding plate 110 and the misalignment separation assembly 130. The direct vibration feeding assembly 120 includes a base frame 124, a direct vibrator 121, and a transmission channel 122. The direct vibrator 121 is disposed on the base frame 124, and the transmission channel 122 is disposed at the power output end of the direct vibrator 121. The feed end of the transmission channel 122 is connected to the vibrating feeding plate 110, and its discharge end is disposed towards the misalignment separation assembly 130, so as to realize the batch directional transmission of the housing 400. The linear vibratory feeding assembly 120 uses the base frame 124 as the overall support and installation reference. The linear vibrator 121 provides stable and continuous linear excitation force. One end of the transmission channel 122 mounted on the power output end of the linear vibrator 121 is connected to the discharge port of the vibratory feeding plate 110, and the other end is arranged towards the misalignment separation assembly 130. The plastic shell workpiece output by the vibratory feeding plate 110 can be stably transported over a long distance through the transmission channel 122, which can buffer the material flow fluctuation caused by the intermittent discharge of the vibratory feeding plate 110 and avoid shell... The 400 shells are concentrated and blocked at the entrance of the separation component. At the same time, the linear unidirectional vibration constrains the conveying posture of the plastic shells, ensuring that all shells 400 are conveyed to the receiving groove 1351 of the platform 135 of the misaligned separation component 130 with a uniform orientation. This isolates the circular vibration of the vibrating feeding tray 110 from being directly transmitted to the misaligned separation component 130, preventing the platform 135 and the shells 400 from being misaligned due to additional vibration interference. This stably connects the feeding and sorting processes, improving the continuity and posture consistency of the plastic shell conveying process.

[0036] Furthermore, the direct vibration feeding assembly 120 also includes a cover plate 123 and a feeding detector 125. The feeding detector 125 is disposed at the feeding end of the transmission channel 122, and the detection end of the feeding detector 125 is disposed facing the inside of the transmission channel 122. The cover plate 123 is fastened to the top of the transmission channel 122. Among them, the feeding detector 125 can detect in real time whether the shell 400 inside the transmission channel 122 is feeding, whether the material is congested, and whether there is a shortage of material. It provides real-time feedback of the material conveying signal to link and control the start and stop of the front-end vibrating feeding plate 110 to achieve adaptive matching of material supply and demand. This avoids excessive accumulation and congestion of the shell 400 inside the channel or the problem of stopping due to material shortage. It ensures that the shell 400 is fed at a uniform speed and in an orderly manner. The cover plate 123, which is fastened to the top of the transmission channel 122, can limit and block the plastic shell during the conveying process, constrain the vertical displacement of the shell 400, and prevent the shell 400 from overturning, jumping out of the channel, or deviating during linear vibration conveying. At the same time, it isolates workshop dust and debris from falling into the transmission channel 122, prevents impurities from getting stuck in the shell 400 and affecting the smoothness of the conveying, and further ensures the directional and stable conveying of the plastic shell throughout the process, improving the feeding stability and feeding qualification rate of the linear vibration feeding component 120.

[0037] In this embodiment, the misalignment separation component 130 further includes a lifting module 132. The lifting module 132 includes a lifting rail 1323, a lifting driver 1322, a lifting frame 1324, and at least two lifting limit blocks 1321. The lifting rail 1323 is disposed on the mounting frame 131 and extends vertically. The lifting driver 1322 is disposed at one end of the lifting rail 1323. The lifting frame 1324 is connected to the power output end of the lifting driver 1322 and is slidably connected to the lifting rail 1323. The platform 135 is connected to the top of the lifting frame 1324 to move synchronously with the lifting frame 1324. The two lifting limit blocks 1321 are respectively connected to the mounting frame 131 and are spaced apart vertically. Each lifting limit block extends horizontally toward the lifting frame 1324 to limit the travel of the lifting frame 1324. The lifting module 132 uses the lifting rail 1323, which is vertically arranged on the mounting frame 131, as the guide reference for the lifting frame 1324. The lifting driver 1322 outputs power to drive the lifting frame 1324 to slide precisely vertically along the lifting rail 1323. The platform 135 is fixed to the top of the lifting frame 1324 and moves up and down synchronously with the lifting frame 1324, thereby changing the height position of the platform 135 and the discharge end of the vertical vibration feeding assembly 120, realizing the sorting action of receiving, isolating and releasing a single shell 400. Two sets of lifting limit blocks 1321, which are installed at intervals along the vertical direction on the mounting frame 131, are horizontally oriented towards the center of the lifting frame 1324. Extending towards the lifting frame 1324, it can physically block and constrain the lifting limit and lowering limit of the lifting frame 1324 respectively, precisely limiting the overall lifting stroke of the lifting frame 1324, avoiding the overshoot of the lifting driver 1322, which could cause the platform 135 to collide with other components or the housing 400 to fall and be damaged. The lifting track 1323 ensures the straightness of the lifting movement, and the lifting driver 1322 provides stable lifting power. With the upper and lower double lifting limit blocks 1321, the stroke is double protected, so that the separation and lifting action of the housing 400 of the platform 135 is smooth and the stroke is controllable, and the separation process of the housing 400 is completed stably.

[0038] Furthermore, the misalignment separation assembly 130 also includes a first limiting module 133 and a second limiting module 134. The first limiting module 133 includes a first limiting driver 1331 and a first limiting member 1332. The first limiting driver 1331 is disposed on the lifting frame 1324 and located at the end of the platform 135 away from the vibrating feeding plate 110. The first limiting member 1332 is connected to the power output end of the first limiting driver 1331 and can extend into the receiving groove 1351 to limit the distance along the length of the platform 135. The second limiting module 134 includes a second limiting driver 1341 and a second limiting member 1342. The second limiting driver 1341 is disposed on the mounting bracket 131, and the second limiting member 1342 is connected to the power output end of the second limiting driver 1341. It can pass through the clearance groove 1353 at the bottom of the platform 135 into the limiting groove 1352 that communicates with one side of the receiving groove 1351 in the width direction, so as to limit the movement of the housing 400 in the width direction of the platform 135.

[0039] The first limiting module 133 and the second limiting module 134 respectively provide bidirectional positioning constraints on the housing 400 within the receiving groove 1351 from two orthogonal directions of length and width. The first limiting driver 1331 is mounted on the lifting frame 1324 and arranged at the end of the platform 135 away from the vibrating feeding plate 110. The first limiting member 1332 connected to its drive output end can extend into the receiving groove 1351 and abut against the end of the housing 400 along the length direction of the platform 135, restricting the housing 400 from moving along the feeding conveying direction. The second limiting driver 1341 is fixed on the mounting frame 131, and the second limiting member 1342 driven by it can pass through the clearance groove 1353 at the bottom of the platform 135 and extend into the limiting groove 1352 that communicates with the width side of the receiving groove 1351. The limit modules abut against the side wall of the housing 400 in the width direction of the platform 135 to constrain the lateral displacement of the housing 400. The two sets of limit modules work together to completely lock the single housing 400 received in the receiving groove 1351 at the preset center positioning position, so as to avoid the housing 400 from shifting back and forth or swaying left and right during the lifting and separation process of the platform 135. This ensures that the picking reference of the gripper 240 of the six-axis robotic arm 210 is consistent each time it grabs the housing 400, eliminates the problem of unstable gripping and skewed gripping caused by the positioning deviation of the housing 400, and improves the alignment accuracy of the subsequent transfer process of the transfer mechanism 200. At the same time, the limit action is linked and synchronized with the lifting and sorting action of the platform 135. The limit locking is only performed after the housing 400 has completely fallen into the receiving groove 1351, so as not to interfere with the feeding and unloading process of the housing 400.

[0040] In this embodiment, the material transfer mechanism 200 undertakes the core conveying functions of plastic shell transfer and alignment insertion. The six-axis robotic arm 210 has multi-degree-of-freedom flexible movement capabilities, enabling multi-angle transfer and precise alignment insertion of plastic shells of different specifications, and adapting to the position adjustment needs of mixed production lines for multiple models of plastic shells. The gripper 240 directly clamps and fixes the plastic shell, and the matching force sensor 230 collects the pressure value of the gripper 240 when clamping the plastic shell in real time, dynamically feeding back the clamping force state. On the one hand, it can limit the clamping peak in real time to avoid excessive clamping force from squeezing and damaging the plastic shell 400 structure. On the other hand, it can identify the empty or slipping conditions due to insufficient clamping force in real time, and promptly trigger supplementary gripping actions to prevent the plastic shell 400 from falling and being scrapped during transfer. Relying on force-controlled clamping combined with a multi-axis motion structure, it takes into account both the safety of plastic shell transfer and the accuracy of insertion alignment, and stably completes the transfer and docking of the separated plastic shell to the terminal assembly station.

[0041] Furthermore, the material transfer mechanism 200 includes an opening and closing driver 220, which is connected to the power output end of the six-axis robotic arm 210. The force sensor 230 is connected to the opening and closing driver 220, and at least two grippers 240 are connected to the power output end of the opening and closing driver 220 to move relative to each other.

[0042] The opening / closing actuator 220 serves as the power source for the relative opening and closing action of the two grippers 240. It can drive at least two sets of grippers 240 to move towards or away from each other to complete the clamping and releasing action of the plastic shell 400. The force sensor 230 is mounted between the opening / closing actuator 220 and the grippers 240. It can collect the pressure data generated by the grippers 240 when clamping the workpiece in real time, continuously monitor the magnitude of the clamping force, and provide real-time feedback of the force signal throughout the entire process of the grippers 240 closing and clamping the plastic shell 400. This allows the opening / closing actuator 220 to reduce the clamping stroke when the clamping force exceeds a set threshold, preventing the grippers from being clamped. Excessive compression of the 240 clamping mechanism causes the plastic shell 400 to crack and deform. However, when the clamping force is detected to be too low or the shell 400 shows a tendency to slip, the clamping force can be increased in time to ensure that the shell 400 will not fall off during the transfer process. The opening and closing action of the gripper 220 is realized by the opening and closing driver 220. With the force sensor 230, the force is controlled in real time in a closed loop. This allows the gripper 240 to maintain a suitable and safe clamping state for plastic shells 400 of different specifications. This ensures that the six-axis robotic arm 210 can transfer the plastic shell 400 stably and reliably throughout the process, and avoids material scrap and assembly misalignment caused by abnormal clamping.

[0043] Specifically, the gripper 240 includes a connecting portion 241, an extension portion 242, and a contoured gripping portion 243. The connecting portion 241 is detachably connected to the power output end of the opening / closing actuator 220. The extension portion 242 extends from the connecting portion 241 in a direction away from the opening / closing actuator 220. The contoured gripping portion 243 is disposed at the free end of the extension portion 242 and configured to match the shape of the outer surface of the housing 400 to be picked up. The gripper 240 is detachably assembled with the power output end of the opening / closing actuator 220 through the connecting portion 241, facilitating quick replacement of the corresponding model gripper 240 according to different shapes and specifications of the plastic housing 400. The replacement can be completed without disassembling the entire gripping drive structure. The extension portion 242, extending from the connecting portion 241 in a direction away from the opening / closing actuator 220, provides sufficient operating space to avoid spatial interference between the opening / closing actuator 220, the end effector of the robotic arm, and the plastic housing 400 or surrounding workstation structures. The free end of the extension portion 242 is integral. The contour of the contoured clamping part 243 is perfectly matched with the outer surface of the housing 400 to be picked up. When clamping, it can fit against the outer wall of the housing 400 over a large area, dispersing the clamping force and preventing local stress concentration from damaging the housing 400. At the same time, the contoured structure achieves circumferential limitation of the housing 400, preventing the housing 400 from slipping or deflecting inside the gripper 240 during transportation. This ensures that the posture of the housing 400 is consistent each time it is picked up, improving the subsequent insertion and alignment accuracy. The overall three-section gripper 240 structure takes into account the convenience of changing the type, the space for movement avoidance, and the stability of clamping and positioning.

[0044] In this embodiment, the combing mechanism 300 is specifically used for the pre-processing of the front end of multiple wire harness terminals. The fixing component 320 uses the terminal clamping plate 322 on the fixing frame 321 to limit and clamp the terminal ends of multiple wire harnesses, pre-lock the position of the terminal root, prevent the terminal from jumping and shifting during the combing process, and provide a reference positioning for the wire harness combing.

[0045] Furthermore, the fixing component 320 includes a clamping driver 323, which is disposed on the fixing frame 321, and the two terminal clamping plates 322 are respectively connected to the power output end of the clamping driver 323. The clamping actuator 323, as the power component for the relative opening and closing of the two terminal clamping plates 322, can synchronously drive the two sets of terminal clamping plates 322 located at its power output end to close towards each other or separate from each other. After the wire harness terminal is fed between the two terminal clamping plates 322, the clamping actuator 323 drives the terminal clamping plates 322 to close, thereby clamping the terminal at the end of the wire harness from both sides. This completes the pre-reference positioning of multiple messy wire harnesses, restricts the end jump and lateral displacement during the combing process, and provides a stable clamping reference for the subsequent combing clamp 333 to separate and comb the wire harness. After completing the regularization work before terminal insertion, the clamping actuator 323 drives the two terminal clamping plates 322 to open to each other, releasing the regularized wire harness terminal to avoid the transfer and insertion action. By relying on the clamping actuator 323 to synchronously control the opening and closing of the two terminal clamping plates 322, the automatic clamping and release of the wire harness terminal is realized, without the need for manual assistance in fixing the wire harness, ensuring that the terminal position is stable and does not deviate during the combing process.

[0046] In this embodiment, the moving component 330 relies on the horizontally arranged moving module 331 to drive the slide 332 and the comb plate 333 to make a horizontal linear feed movement. The toothed comb plate 333 moves with the slide 332 and inserts into the gaps between multiple wire harnesses, separating and opening up the originally messy and intertwined wire harnesses one by one, uniformly limiting the spacing between each terminal, eliminating the problem of terminal misalignment and crossing, and keeping all terminals in a neat and parallel posture. The neatly arranged multiple terminals can be synchronously and accurately aligned with the 400 pin slots of the plastic shell for insertion. This solves the defects of easy interference and large alignment deviation in the synchronous insertion of multiple terminals from the front-end process, greatly reducing defects such as terminal bending, plating scratches, and improper assembly, and improving the assembly qualification rate of synchronous insertion of multiple terminals.

[0047] Furthermore, the moving component 330 includes a rotary driver 336, a transmission screw 335, and two transmission plates 334. The rotary driver 336 is disposed on the top of the carriage 332. The transmission screw 335 extends vertically and one end is connected to the power output end of the rotary driver 336. The two transmission plates 334 are connected to the transmission screw 335 through threaded sleeves 3341 disposed thereon. The thread structures of the two threaded sleeves 3341 are arranged oppositely to drive the two transmission plates 334 to move relative to each other. The combing clamps 333 are respectively connected to the two transmission plates 334.

[0048] The rotary actuator 336 provides rotational power for the opposing opening and closing action of the comb clamp 333. One end of the vertically arranged transmission screw 335 is connected to the power output end of the rotary actuator 336 to synchronously receive rotational torque. Two transmission plates 334 are mounted on the outside of the transmission screw 335 via their respective threaded sleeves 3341. The two threaded sleeves 3341 adopt a thread structure with opposite directions of rotation. When the rotary actuator 336 drives the transmission screw 335 to rotate in the forward or reverse direction, the two threaded sleeves 3341 can synchronously drive the corresponding transmission plates 334 to make linear movements of moving towards each other or separating from each other. They are respectively fixed on the two transmission plates. The combing clamps 333 on plate 334 open and close synchronously, which can separate and comb multiple wire harnesses after pre-clamping and positioning. The reverse threaded screw drive structure can ensure that the movement stroke of the combing clamps 333 on both sides is completely synchronized. During the combing process, each wire harness is subjected to uniform force, and there will be no situation of single-sided wire harness squeezing and deviation. Relying on the cooperation of the rotary driver 336, the vertical drive screw 335 and the positive and negative threaded sleeves 3341, the double combing clamps 333 open and close smoothly and synchronously, accurately completing the sorting and straightening of multiple wire harness terminals, ensuring that the spacing of all terminals is uniform and the posture is consistent after combing, providing a reliable pre-processing foundation for subsequent synchronous and accurate insertion.

[0049] The wire harness terminal batch insertion equipment in this embodiment includes a control mechanism and multiple housing feeding mechanisms 100. The multiple housing feeding mechanisms 100 respectively feed and transfer housings 400 of different models. The multiple housing feeding mechanisms 100, the material transfer mechanism 200 and the wire combing mechanism 300 are respectively connected to the control mechanism. The control mechanism serves as the central hub for the unified scheduling of the entire machine. Multiple housing feeding mechanisms 100 can independently complete directional conveying, separation, and sorting operations for different specifications and models of plastic housings 400, thereby simultaneously supplying materials for various assembly housings 400. Each housing feeding mechanism 100, transfer mechanism 200, and combing mechanism 300 is electrically connected to the control mechanism. The control mechanism can coordinate the timing actions of each mechanism according to the preset assembly program. It can automatically switch to activate the corresponding housing feeding mechanism 100 according to the production order requirements, and synchronously link the combing mechanism 300 to complete the straightening of wire harness terminals, and the transfer mechanism 200 to complete the picking, transfer, and terminal insertion of housings 400. This enables automated assembly of mixed wire harness terminals for multiple models of plastic housings 400 without stopping the machine to change the entire set of feeding tooling, significantly shortening the product changeover waiting time. At the same time, the control mechanism collects the operating status of each mechanism, material detection signals, and clamping force feedback data in real time, realizing closed-loop control of the entire machine's actions. This ensures orderly and interference-free collaborative actions of multiple workstations, effectively improving the equipment's production flexibility and the ability to simultaneously mass-produce multiple types of wire harness connectors.

[0050] Example 2: This example provides a method for batch insertion of wire harness terminals. It uses the batch insertion equipment for wire harness terminals described in Example 1. The method uses a material transfer mechanism 200 to drive the housing 400 to perform batch insertion and assembly with multiple wire harness terminals after combing. The material transfer mechanism 200 adjusts its clamping transmission force in real time through a force sensor 230 to adaptively match the clamping requirements of housings 400 with different shapes, materials and specifications, thereby improving the product compatibility of the equipment. It works in conjunction with the housing feeding process and the terminal combing process to complete automated batch insertion.

[0051] The shell loading process includes:

[0052] Step S1: The shells 400 to be assembled are transported in batches through the vibrating feeding tray 110, thereby realizing continuous and directional automated feeding and conveying of a large number of shells 400, ensuring uninterrupted supply of materials for shells 400, and maintaining continuous mass production of the assembly process.

[0053] Step S2: When the housing 400 to be assembled moves to the platform 135 of the misalignment separation component 130, the platform 135 is driven to rise to separate the individual housing 400 to be assembled. The lifting and misalignment action of the platform 135 completely separates the individual housing 400 from the stacked housing 400 at the rear end, so as to realize the individual housing 400 is discharged one by one, eliminating the problem of stacked housing 400 jamming and sticking during discharge, and ensuring that the six-axis robotic arm 210 gripper 240 accurately grasps the individual housing 400 in one go.

[0054] The terminal connection wire sorting process includes:

[0055] Step a: Place the terminal to be assembled in the fixing component 320. Use the fixing component 320 to complete the reference clamping and positioning of the wire harness terminal end, lock the initial position of the terminal, avoid the terminal bouncing and offset during the subsequent combing process, and establish a stable combing reference.

[0056] Step b: The connecting wires of the separator terminals are clamped by the comb clamp 333 in the moving component 330 to complete the partitioning and limiting clamping of the messy wire harness and achieve the initial partitioning and isolation of the wire harness;

[0057] Step c: Drive the comb plate 333 to move, and horizontally disperse and comb the multiple wire bundles after clamping them. Evenly separate the multiple terminal wire bundles that are messy and interfering with each other, uniformly calibrate the spacing and overall posture of each terminal, eliminate the problem of terminal cross-misalignment, and lay the process foundation for subsequent multi-terminal synchronous and precise alignment of the housing 400 to complete batch plugging.

[0058] In summary, the wire harness terminal batch insertion equipment and method of the present invention, through the coordinated operation of the housing feeding mechanism 100, the material transfer mechanism 200, and the wire combing mechanism 300, firstly relies on the vibrating feeding tray 110 to achieve continuous automated feeding of the plastic housing 400, and then uses the vertically lifting and lowering staggered separation component 130 platform 135 to separate individual housings 400 one by one, avoiding stacking and jamming of housings 400, and ensuring that housings 400 are output in an orderly and individual manner. Then, a six-axis robotic arm 210 equipped with a force sensor 230, together with a gripper 240, accurately picks up the housing 400. The force sensor 230 can provide real-time feedback on the clamping force status, which can prevent the gripper 240 from applying excessive clamping force and damaging the plastic housing. The body 400 can avoid slippage caused by insufficient clamping force, improve the stability and protection effect of the housing 400 during transportation, and at the same time set up an independent combing mechanism 300 to pre-process multiple messy wire harness terminals. The terminal clamping plate 322 of the fixed component 320 first completes the positioning and clamping of the wire harness end terminals. Then, the moving module 331 drives the slide 332 and the combing plate 333 to move horizontally. The toothed structure of the combing plate 333 separates and combs multiple wire harnesses, effectively eliminating the problems of wire harness terminals being tangled and misaligned. After being straightened, the terminals can maintain a uniform spacing and posture, which is convenient for subsequent synchronous and precise insertion with the plastic housing 400.

[0059] In this complete set of equipment, the various mechanisms work together to achieve automatic material distribution and transfer of housing 400 and automatic sorting and arrangement of wire harness terminals in an integrated operation. There is no need for manual sorting of wire harnesses and housing 400, which greatly reduces the intensity of manual operation. At the same time, it can adapt to the assembly needs of different specifications of plastic housing 400 and a large number of wire harness terminals, reduce downtime losses caused by frequent tooling changes, improve the flexibility of the production line, improve the terminal insertion and alignment accuracy, reduce the output of defective products such as terminal bending, plating scratches, and assembly misalignment, and significantly improve the overall assembly efficiency and finished product assembly consistency of wire harness connectors.

[0060] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A batch insertion device for wire harness terminals, characterized in that: include: The housing feeding mechanism includes a vibrating feeding plate and a misalignment separation component. The housing to be assembled is fed through the vibrating feeding plate. The misalignment separation component includes a mounting frame and a platform. The mounting frame is located at the component output end of the vibrating feeding plate. The platform can slide vertically connected to the mounting frame and has an internal receiving groove for receiving a single housing. The material transfer mechanism includes a six-axis robotic arm, a force sensor, and a gripper. The six-axis robotic arm is disposed on one side of the misalignment separation component, and the gripper is disposed on the moving end of the six-axis robotic arm to grip the housing. The detection end of the force sensor is connected to the gripper. A combing mechanism includes a combing frame, a fixing component, and a moving component. The combing frame is disposed on one side of the material transfer mechanism. The fixing component and the moving component are both disposed on the combing frame. The fixing component includes a fixing frame and a terminal clamping plate. The fixing frame is fixedly connected to one side of the combing frame, and the terminal to be assembled can be clamped and fixed in the terminal clamping plate. The moving component includes a moving module, a slide, and a combing clamp. The moving module is horizontally disposed on the combing frame. The slide is slidably connected to the moving module. The combing clamp is disposed on the slide to clamp the separating terminal connecting wire.

2. The batch insertion equipment for wire harness terminals according to claim 1, characterized in that: The shell feeding mechanism further includes a direct vibration feeding assembly, which is disposed between the vibrating feeding plate and the misalignment separation assembly. The direct vibration feeding assembly includes a base frame, a direct vibrator, and a transmission channel. The direct vibrator is disposed on the base frame, and the transmission channel is disposed at the power output end of the direct vibrator. The feed end of the transmission channel is connected to the vibrating feeding plate, and its discharge end is disposed towards the misalignment separation assembly for batch directional transmission of shells.

3. The batch insertion equipment for wire harness terminals according to claim 2, characterized in that: The direct vibration feeding assembly also includes a cover plate and a feeding detector. The feeding detector is disposed at the feed end of the transmission channel, and the detection end of the feeding detector is disposed facing the inside of the transmission channel. The cover plate is fastened to the top of the transmission channel.

4. The batch insertion equipment for wire harness terminals according to claim 1, characterized in that: The misalignment separation assembly further includes a lifting module, which includes a lifting rail, a lifting driver, a lifting frame, and at least two lifting limit blocks. The lifting rail is disposed on the mounting frame and extends vertically. The lifting driver is disposed at one end of the lifting rail. The lifting frame is connected to the power output end of the lifting driver and slidably connected to the lifting rail. The platform is connected to the top of the lifting frame to move synchronously with the lifting frame. The two lifting limit blocks are respectively connected to the mounting frame and are spaced apart vertically. Each lifting limit block extends horizontally toward the lifting frame to limit the movement stroke of the lifting frame.

5. The batch insertion equipment for wire harness terminals according to claim 1, characterized in that: The misalignment separation assembly further includes a first limiting module and a second limiting module. The first limiting module includes a first limiting driver and a first limiting member. The first limiting driver is disposed on the lifting frame and located at the end of the platform away from the vibrating feeding plate. The first limiting member is connected to the power output end of the first limiting driver and can extend into the receiving groove to limit the movement position of the housing in the length direction of the platform. The second limiting module includes a second limiting driver and a second limiting member. The second limiting driver is disposed on the mounting frame. The second limiting member is connected to the power output end of the second limiting driver and can pass through the clearance groove at the bottom of the platform to the limiting groove communicating with one side of the receiving groove in the width direction to limit the movement position of the housing in the width direction of the platform.

6. The batch insertion equipment for wire harness terminals according to claim 1, characterized in that: The material handling mechanism includes an opening and closing driver connected to the power output end of the six-axis robotic arm, a force sensor connected to the opening and closing driver, and at least two grippers connected to the power output end of the opening and closing driver for relative opening and closing movement.

7. The batch insertion equipment for wire harness terminals according to claim 6, characterized in that: The gripper includes a connecting portion, an extension portion, and a contoured clamping portion. The connecting portion is detachably connected to the power output end of the opening and closing driver. The extension portion extends from the connecting portion in a direction away from the opening and closing driver. The contoured clamping portion is disposed at the free end of the extension portion and is configured to match the shape of the outer surface of the housing to be assembled.

8. The batch insertion equipment for wire harness terminals according to claim 1, characterized in that: The moving component includes a rotary driver, a lead screw, and two transmission plates. The rotary driver is located on the top of the carriage. The lead screw extends vertically and one end is connected to the power output end of the rotary driver. Both transmission plates are connected to the lead screw via threaded sleeves. The thread structures of the two threaded sleeves are opposite to drive the two transmission plates to move relative to each other. The combing clamps are respectively connected to the two transmission plates. The fixing component includes a clamping driver, which is mounted on the fixing frame, and the two terminal clamping plates are respectively connected to the power output end of the clamping driver.

9. The batch insertion equipment for wire harness terminals according to claim 1, characterized in that: The wire harness terminal batch insertion equipment includes a control mechanism and multiple housing feeding mechanisms. The multiple housing feeding mechanisms respectively feed and transfer housings of different models. The multiple housing feeding mechanisms, the material transfer mechanism, and the wire combing mechanism are respectively connected to the control mechanism.

10. A method for batch insertion of wire harness terminals, characterized in that: The wire harness terminal batch insertion equipment according to any one of claims 1 to 9 is used for batch insertion of wire harness terminals. It uses a material transfer mechanism to drive the housing to batch insert and assemble multiple wire harness terminals after combing. The material transfer mechanism adjusts its clamping and transmission force in real time through a force sensor to ensure compatibility with different housings. The shell loading process includes: Step S1: Batch transfer of housings to be assembled using a vibrating feeding tray; Step S2: When the housing to be assembled moves into the stage of the misalignment separation assembly, drive the stage to rise to separate the individual housings to be assembled. The terminal connection wire sorting process includes: Step a: Place the terminals to be assembled into the fixing assembly; Step b: Clamp the separator terminal connection wire using the comb clamp in the moving assembly; Step c: Drive the comb plate to move to comb the terminal connection wires.

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