A high-precision multi-terminal shell positioning jig, shell inserting equipment and shell inserting method

Abstract

The application relates to a high-precision multi-terminal shell positioning jig, a shell inserting device and a shell inserting method. The positioning jig comprises a base, a plastic shell profiling structure, a concentric limiting structure, a lifting device and a contact end limiting structure. The plastic shell profiling structure is provided with a profiling through slot for accommodating a plastic shell with terminal insertion holes. The concentric limiting structure is provided with a plurality of concentric limiting portions which are coaxially arranged in one-to-one correspondence with the terminal insertion holes of the plastic shell. The lifting device comprises a plurality of lifting pieces in one-to-one correspondence with the concentric limiting portions. The contact end limiting structure is configured to limit the terminal contact end. The automatic shell inserting device comprises the above positioning jig and adopts a pure mechanical structure to insert the terminal. The automatic shell inserting method adopts a secondary crimping mode to accurately crimp on the basis of terminal positioning of the automatic shell inserting device. The application realizes high-precision automatic shell inserting of the terminal through the above setting, and improves the terminal shell inserting qualification rate.

Description

Technical Field

[0001] This invention relates to the fields of wire harness processing and electrical connector assembly, and in particular to a high-precision multi-terminal housing positioning fixture, housing insertion equipment, and housing insertion method. Background Technology

[0002] In the field of new energy vehicle wiring harness processing, the assembly of terminals and plastic shells is one of the key processes in connector manufacturing. With the rapid development of the new energy vehicle industry, the demand for production capacity and quality requirements for wiring harness connectors is constantly increasing, and traditional shell assembly methods can no longer meet the needs of large-scale, high-precision production.

[0003] Currently, shell assembly mainly relies on manual operation or semi-automatic equipment. Manual shell assembly depends heavily on operator skill, resulting in low production efficiency, high labor intensity, and a high rate of defects such as bent terminals and damaged shells, failing to meet the demands of large-scale production. Therefore, the industry has begun developing automated shell assembly equipment.

[0004] However, existing automated terminal insertion equipment still has many shortcomings. First, most equipment adopts a single-station operation mode, which can only perform terminal insertion operations on one terminal or a group of terminals at a time, resulting in limited capacity and difficulty in meeting the needs of large-scale continuous production. The few equipment that adopt dual-station or multi-station designs have redundant structural designs, poor coordination between stations, and messy wiring and piping, resulting in insufficient operational stability.

[0005] Secondly, the positioning fixtures in existing equipment lack dedicated guiding and limiting structures. The terminal contact ends are prone to horizontal misalignment after being placed into the fixture, resulting in insufficient concentricity between the terminal and the plastic housing socket. Under these conditions, crimping can easily cause the terminal to bend or the plastic housing to break, severely impacting the product's electrical performance and mechanical reliability.

[0006] Furthermore, existing fixtures mostly employ rigid support structures, making it impossible to uniformly limit the placement height of multiple terminals. Due to individual differences or assembly errors between terminals, the placement height of each terminal is inconsistent. When multiple terminals are pressed down simultaneously, some terminals are subjected to excessive force and deform, while others are not properly crimped, resulting in poor product consistency and a high defect rate. In addition, traditional equipment often uses cylinders to drive moving parts such as slides. The moving workstations are accompanied by a large number of wiring harnesses and pneumatic pipelines. These lines and pipelines are prone to wear, aging, and jamming after long-term operation, resulting in insufficient equipment stability and high maintenance costs.

[0007] In addition, the rigid support structure at the bottom of the existing fixture cannot effectively avoid the terminal after crimping. When the crimping mechanism retracts, the rigid support structure can easily push the terminal that has been pressed into the plastic shell out in the opposite direction, causing the terminal to loosen or the crimping depth to be insufficient, which further reduces the product yield.

[0008] In summary, existing insertion equipment and positioning fixtures have significant shortcomings in terms of production efficiency, positioning accuracy, terminal placement height consistency, drive mode stability, and post-press avoidance. There is an urgent need for insertion equipment and positioning fixtures that can achieve high precision, high efficiency, and high stability. Summary of the Invention

[0009] Therefore, the technical problem to be solved by the present invention is to overcome the problems in the prior art, such as the lack of guidance and positioning of terminals, resulting in poor concentricity between terminals and plastic shell insertion holes, which easily damages the workpiece during crimping; the inconsistent height of terminals placed inside the plastic shell, leading to terminal scraping and high product defect rate after pressing; the problem of multiple wire harnesses, wear of air pipes over time, and insufficient equipment operation stability caused by the direct drive of cylinders for lifting components; and the problem of the bottom support structure pushing the terminals after crimping, resulting in unqualified crimping depth. Thus, the present invention provides a high-precision multi-terminal insertion shell positioning fixture, insertion shell equipment, and insertion shell method.

[0010] To address the aforementioned technical problems, in a first aspect, the present invention provides a high-precision multi-terminal housing positioning fixture for positioning multiple terminals within a plastic housing. The fixture includes a base, a plastic housing conforming structure, a concentric limiting structure, a lifting device, and a contact end limiting structure. The plastic housing conforming structure is disposed on the base and has a conforming through groove for accommodating the plastic housing with terminal insertion holes. The concentric limiting structure is disposed between the plastic housing conforming structure and the base, and has multiple concentric limiting portions that correspond one-to-one with the terminal insertion holes of the plastic housing and are coaxially arranged. The lifting device is disposed below the base and includes multiple lifting members that can pass through the base and correspond one-to-one with the multiple concentric limiting portions. The contact end limiting structure is slidably disposed on one side of the concentric limiting structure and is configured to limit the contact ends of the terminals.

[0011] In one embodiment of the present invention, each of the multiple concentric limiting parts has a guide channel, the guide channel being coaxially arranged with the terminal socket of the plastic shell, and the guide channel being configured to keep the terminal and the terminal socket of the plastic shell coaxial.

[0012] In one embodiment of the present invention, the lifting member has a pushing state and a disengaging state. In the pushing state, the lifting member is configured to push the terminal inserted into the guide channel to the same horizontal height. In the disengaging state, the lifting member is configured to disengage from the terminal after crimping.

[0013] In one embodiment of the present invention, the base is provided with a through hole for the lifting component to pass through, and the contoured through groove of the plastic shell contouring structure matches the outer contour of the plastic shell.

[0014] In one embodiment of the present invention, the contact end limiting structure has a guide groove, which is arranged parallel to the central axis of the terminal socket of the plastic shell and corresponds one-to-one with the terminal socket. It is configured such that after the terminal is inserted into the plastic shell, it slides toward the terminal to limit the contact end of the terminal.

[0015] In one embodiment of the present invention, the length of the guide slot is greater than the lifting stroke of the lifting component.

[0016] In one embodiment of the present invention, the lateral dimension of the guide slot opening side is greater than the lateral dimension of the guide slot bottom side, and the guide slot and the terminal contact end form a clearance fit.

[0017] Secondly, the present invention provides a high-precision multi-terminal automatic shell insertion device, characterized in that the device includes: a frame having a worktable, at least one of the above-mentioned high-precision multi-terminal shell insertion positioning fixtures disposed on the worktable, a lifting drive mechanism being connected to the lifting device of the positioning fixture for driving the lifting device to lift, and at least one pressing module being disposed above the at least one positioning fixture, wherein the at least one pressing module includes a pressing block.

[0018] In one embodiment of the present invention, the insert device further includes at least one servo slide mounted on a worktable. Each servo slide is independently driven and configured to operate synchronously or alternately to drive the positioning fixture to reciprocate along a linear direction. In another embodiment of the present invention, the insert device further includes at least one sliding drive mechanism, which slides in cooperation with the contact end limiting structure to drive the contact end limiting structure to slide closer to or away from the terminal contact end.

[0019] Thirdly, the present invention also provides a high-precision multi-terminal automatic shell insertion method, comprising:

[0020] S1: Position the plastic shell, insert the terminal into the terminal socket of the plastic shell, and guide the terminal axially once to keep the terminal and the terminal socket of the plastic shell coaxial;

[0021] S2: Push the terminal to the same height;

[0022] S3: Perform secondary circumferential guidance on the terminals to align them circumferentially with the terminal sockets of the plastic housing;

[0023] S4: Pre-press the terminals to keep the terminal necks at the same height, then release the push on the terminals;

[0024] S5: Final pressure is applied to the terminals to complete the synchronous insertion of multiple terminals into the housing;

[0025] S6: Remove the plastic shell with the inserted terminal.

[0026] In one embodiment of the present invention, the plastic shell in step S1 is positioned by the plastic shell contouring structure; the axial guidance is achieved by the guide channel of the concentric limiting part, and the lower part of the terminal enters the guide channel after passing through the plastic shell, and the guide channel axially guides the terminal that passes through.

[0027] In one embodiment of the present invention, in step S2, the terminals are pushed up by the lifting device to keep the terminals at the same height.

[0028] In one embodiment of the present invention, the secondary circumferential guidance in step S3 is achieved by the guide groove of the contact end limiting structure cooperating with the terminal contact end to correct the circumferential orientation of the terminal and align the terminal with the terminal socket of the plastic shell in the circumferential direction.

[0029] In one embodiment of the present invention, in step S4, the terminals are pre-pressed by pressing down the crimping module so that the neck of each terminal is held by the crimping module, and then the lifting device is driven to disengage from the terminals.

[0030] In one embodiment of the present invention, in step S5, the terminals are pressed down further by the crimping module to complete the synchronous insertion of multiple terminals.

[0031] Compared with the prior art, the above-described technical solution of the present invention has the following advantages:

[0032] The high-precision multi-terminal insertion housing positioning fixture of this invention adopts a multi-positioning structure, resulting in excellent insertion accuracy. Through the contact end limiting structure and the terminal housing concentric limiting structure, high concentricity between the terminal and the insertion hole of the plastic housing is ensured, effectively preventing defects such as terminal bending and plastic housing scratches.

[0033] The lifting component described in this invention can achieve equal height support for the terminals, resulting in good product consistency. By unifying the placement height of all terminals, the pressing depth of each terminal is uniform and stable after synchronous pressing during crimping.

[0034] The lifting component described in this invention can actively avoid collisions, preventing the terminals from being pushed out. After crimping, the driver moves the lifting component to sink and detach from the terminal. It will not push the terminal during station movement and material discharge, effectively preventing the terminal from loosening and insufficient crimping depth, and significantly improving the yield rate.

[0035] The high-precision multi-terminal automatic shell insertion equipment described in this invention can adopt multi-station parallel operation, resulting in high production efficiency. Multiple sets of servo slides alternately complete the feeding and crimping processes without interference, significantly increasing the production capacity compared to traditional single-station equipment and making it suitable for mass production.

[0036] The high-precision multi-terminal automatic shell insertion device described in this invention adopts a purely mechanical drive structure, which is simple in structure and has low maintenance costs. The mechanical transmission structure is simple and intuitive, with few parts, making daily inspection and maintenance convenient, and suitable for long-term continuous operation in industrial sites.

[0037] The high-precision multi-terminal automatic shell insertion method of this invention combines a crimping module with a lifting device. A positioning fixture pre-positions the terminals, and a pressure block pre-presses to precisely support the terminals before final crimping. By using the positioning fixture to coaxially orient the terminals and the lifting device to support them at the same height, the pressure block can accurately support the terminals in the predetermined ideal position, thus facilitating precise crimping. Attached Figure Description

[0038] 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.

[0039] Figure 1 This is a schematic diagram of a high-precision multi-terminal insertion shell positioning fixture according to the present invention;

[0040] Figure 2 is a schematic diagram of the plastic shell and terminal processed by a positioning fixture according to the present invention, wherein... Figure 2a This is a front view of the plastic shell. Figure 2b This is a schematic diagram of the bottom structure of the plastic shell. Figure 2c This is a schematic diagram of the terminals;

[0041] Figure 3 This is a schematic diagram of the concentric limiting structure of the high-precision multi-terminal insertion housing positioning fixture of the present invention;

[0042] Figure 4 This is a rear side view of the lifting device of the high-precision multi-terminal insertion housing positioning fixture of the present invention;

[0043] Figure 5 This is a schematic diagram of the plastic shell conformal structure of the high-precision multi-terminal insertion shell positioning fixture of the present invention;

[0044] Figure 6 This is a schematic diagram of the contact end limiting structure of the high-precision multi-terminal insertion housing positioning fixture of the present invention;

[0045] Figure 7 is a schematic diagram of the high-precision multi-terminal automatic shell insertion device of the present invention, wherein... Figure 7a This is a schematic diagram of the overall insert device. Figure 7b A schematic diagram of the insert housing after the upper frame housing has been removed; Figure 7c for Figure 7b A partially enlarged schematic diagram of point A (where the pressure block is not pressing down to support the neck of the terminal); Figure 7d for Figure 7b A partially enlarged schematic diagram of point A (the neck of the terminal supported by the pressure block).

[0046] Explanation of reference numerals in the accompanying drawings: 1. Positioning fixture; 11. Base; 12. Plastic shell contouring structure; 121. Plastic shell; 1211. Terminal socket; 1212. Upper plate; 1213. Hollow shell; 122. Terminal; 1221. Terminal contact end; 1222. Terminal neck; 1223. Terminal crimping end; 13. Concentric limiting structure; 131. Concentric limiting part; 14. Lifting device; 141. Lifting component; 15. Contact end limiting structure; 151. Guide slot; 2. Frame; 3. Servo slide; 4. Crimping module; 41. Pressing block. Detailed Implementation

[0047] 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.

[0048] Example 1:

[0049] Reference Figure 1 As shown, a high-precision multi-terminal socket positioning fixture 1 of the present invention is used to fix multiple terminals within a plastic shell 121. It includes a base 11, a plastic shell contouring structure 12, a concentric limiting structure 13, a lifting device 14, and a contact end limiting structure 15. The plastic shell contouring structure 12 is disposed on the base 11 and has a contoured through groove for accommodating the plastic shell 121. The plastic shell 121 has multiple terminal sockets 1211. The concentric limiting structure 13 is disposed between the plastic shell contouring structure 12 and the base 11. The concentric limiting structure 13 has multiple concentric limiting parts 131, each corresponding to and coaxially arranged with the terminal sockets 1211 of the plastic shell 121. The lifting device 14 is disposed below the base 11 and includes multiple lifting members 141, which can pass through the base 11 and correspond one-to-one with the multiple concentric limiting parts 131. The contact end limiting structure 15 is slidably disposed on one side of the concentric limiting structure 13, and the contact end limiting structure 15 is configured to limit the terminal contact end.

[0050] In this embodiment, the terminal 122 structure includes a contact end 1221, a neck 1222, and a crimping end 1223. After the terminal 122 is inserted into the plastic shell 121, its crimping end 1223 is held in the plastic shell 121 by a locking mechanism inside the plastic shell. The plastic shell 121 has multiple terminal insertion holes 1211, which can be of various types to match the desired inserted terminal 122. A locking mechanism is provided inside each terminal insertion hole 1211 to hold the crimping end 1223. A specific type of plastic shell is shown in Figure 2. The plastic shell 121 includes an upper plate portion 1212 and a hollow shell portion 1213 disposed below the upper plate portion 1212. Multiple terminal insertion holes 1211 extending vertically are provided on the upper plate portion 1212, and each terminal insertion hole 1211 is used to accommodate and position the terminal 122. The hollow housing portion 1213 has an internal receiving space for accommodating the lower part of the terminal 122 that protrudes from the upper plate portion 1212, and provides clearance space for the insertion of the terminal 122. It is shaped to facilitate the insertion of the terminal and match the external connector structure.

[0051] The lifting device 14 moves vertically up and down via a cam follower to push and disengage the lifting component 141 from the terminal. The lifting device 14 is located below the base 11 and can move along with the base 11 as a whole. The lifting component 141 can be fixedly mounted on a support plate, which can be driven to rise and fall independently relative to the base 11 via a cam follower.

[0052] Specifically, the concentric limiting part 13 can correspond one-to-one with the terminal socket 1211 of the plastic shell 121, or it can be set according to the structure of the plastic shell and the push requirements of the terminals inserted in the plastic shell. That is to say, not every socket of the plastic shell is provided with a concentric limiting part 131.

[0053] Furthermore, each of the multiple concentric limiting parts 131 has a guide channel, which is coaxially arranged with the terminal socket 1211 of the plastic shell 121. The guide channel is configured to keep the terminal 122 and the terminal socket 1211 of the plastic shell 121 coaxial.

[0054] In this embodiment, the inner wall of the guide channel forms a clearance fit with the outer peripheral surface of the terminal 122, limiting the axial and radial movement of the terminal 122. Throughout the entire process of the terminal 122 being inserted from above the plastic shell 121, passing through the plastic shell 121, entering the guide channel, and until the crimping is completed, the inner wall of the guide channel always constrains the radial displacement of the terminal 122, ensuring that the central axis of the terminal 122 remains coaxial with the central axis of the terminal insertion hole 1211 of the plastic shell 121.

[0055] Furthermore, the lifting member 141 supports the terminal 122, keeping the terminal neck 1222 at the same horizontal height. The base 11 has a through hole for the lifting member 141 to pass through. Preferably, the through hole corresponds one-to-one with the lifting member 141 and is coaxially arranged. The lifting member 141 can be clearance-fitted with the through hole and is positioned axially and radially by the through hole. The contoured through groove of the plastic shell contouring structure 12 matches the outer contour of the plastic shell 121.

[0056] In this embodiment, the concentric limiting structure 13 is fixedly disposed above the base 11, and the plastic shell conforming structure 12 is fixedly disposed above the concentric limiting structure 13.

[0057] like Figure 3 As shown, the concentric limiting structure 13 includes a base plate and a concentric limiting part 131. The base plate has multiple through holes, which correspond one-to-one with the terminal insertion holes 1211 of the plastic shell 121 to be placed in the plastic shell conforming structure 12 and are coaxially arranged. The base plate can be correspondingly set into a stepped shape, and its shape can be set according to the structure of the plastic shell conforming structure 12 and the plastic shell to meet the optimal positioning of the plastic shell and the optimal pushing effect of the terminal in the plastic shell. The concentric limiting part 131 is a hollow structure, which can be a hollow cylinder, a hollow tube or a stepped hollow cylinder. The bottom of the stepped hollow cylinder is a large diameter section with a larger diameter, and the top is a small diameter section with a smaller diameter. The through holes match its outer contour and are also stepped through holes with a large diameter at the bottom and a small diameter at the top. Thus, the large diameter section at the bottom of the stepped hollow cylinder can be engaged in the large diameter hole at the bottom of the through hole, which facilitates the stable fixing of the concentric limiting part 131. In a fixed state, the concentric limiting structure 13 and the plastic shell conforming structure 12 have a concentric limiting part 131, which is a hollow cylinder, hollow tube, or stepped hollow cylinder, protruding from the substrate and passing through the conforming groove or conforming positioning cavity of the plastic shell conforming structure 12. This corresponds one-to-one with the terminal socket 1211 of the plastic shell 121 inserted into the plastic shell conforming structure 12, and provides concentric guidance for the terminal 122 inserted into the plastic shell 121. After the terminal 122 is inserted into the terminal socket 1211 of the plastic shell 121, it enters the guide slot of the concentric limiting part 131 below, correcting the insertion direction of the terminal. This ensures that the terminal and the terminal socket are always on the same central axis, avoiding the situation where the terminal cannot be accurately coaxially inserted when inserted into the terminal socket, which may cause tilting and poor crimping during the terminal crimping process, thus improving the yield.

[0058] Specifically, each concentric limiting part of the concentric limiting structure 13 is further provided with a lifting member 141 guide structure below it. This structure extends below the concentric limiting structure 13 and is used to guide and limit the lifting of the lifting member 141.

[0059] Furthermore, the lifting member 141 has a pushing state and a disengaging state. In the pushing state, the lifting member 141 is configured to push the terminal inserted into the guide channel to the same horizontal height. In the disengaging state, the lifting member 141 is configured to disengage the terminal after crimping.

[0060] In this embodiment, as Figure 4 As shown, the lifting component 141 can specifically be pin-shaped. After the terminal is fed, the drive mechanism drives the lifting component 141 to move upward. During this process, the lifting component 141 supports the terminal neck to the same height, in a pushing state, which facilitates keeping the terminal neck at the same height during the insertion process, ensuring high-precision insertion between the terminal and the housing. After crimping is completed, the lifting component 141 is driven by the drive mechanism (such as a purely mechanical cam mechanism) to move downward actively, so that the top of the lifting component 141 is lower than the bottom of the terminal and the plastic housing, realizing the separation of the lifting component 141 from the terminal and preventing the crimped terminal from being pushed out in the opposite direction.

[0061] In this embodiment, as Figure 5 As shown, the contouring groove of the plastic shell contouring structure 12 is contoured to the outer contour of the plastic shell 121, enabling it to form a surface or line contact fit with the plastic shell 121. This contouring positioning cavity only allows the plastic shell to be inserted in a single predetermined direction, forming a mistake-proof positioning to improve the accuracy of manual loading. The outer contour shape of the plastic shell can be adaptively designed according to actual application requirements, and is not limited to a specific shape. Accordingly, the contouring positioning cavity of the plastic shell contouring structure can be adjusted according to the actual outer contour shape of the plastic shell to adapt to plastic shells of different specifications, thereby realizing the universal design of the positioning fixture of this application.

[0062] In this embodiment, the plastic shell contouring structure 12, the concentric limiting structure 13, and the base 11 are precisely positioned in pairs through positioning pins and positioning holes. The plastic shell contouring structure 12, the concentric limiting structure 13, and the base 11 form an integral installation unit.

[0063] Furthermore, the contact end limiting structure 15 has a guide groove 151, which is parallel to the central axis of the terminal insertion hole 1211 of the plastic shell 121 and corresponds one-to-one with the terminal insertion hole 1211. It is configured such that after the terminal 122 is inserted into the plastic shell 121, it slides toward the terminal 122 to limit the terminal contact end 1221.

[0064] Furthermore, the length of the guide slot 151 is greater than the lifting stroke of the lifting member 141 to ensure that the terminal 122 remains within the constraint range of the guide slot 151 during insertion and removal. (Refer to...) Figure 1 or Figure 6As shown, the guide slot 151 extends along the terminal insertion direction, and its extension length is greater than the lifting stroke of the lifting member 141 pushing the terminal. The guide slot 151 can laterally limit the terminal throughout the entire stage from terminal feeding to completion of crimping and discharge, ensuring high-precision insertion of the terminal shell.

[0065] Furthermore, the lateral dimension of the opening side of the guide slot 151 is larger than the lateral dimension of the bottom side of the guide slot 151, and the guide slot 151 and the contact end of the terminal 122 form a clearance fit.

[0066] In this embodiment, the contact end limiting structure 15 includes a slide rail, a slider, and a guide slot 151. The slide rail is fixed above the base and is disposed on one side of the plastic shell contouring structure 12 and the concentric limiting structure 13. The contact end limiting structure 15 is used to limit the predetermined orientation of the terminal 122 to be inserted into the plastic shell 121. For example, the contact end limiting structure 15 limits the terminal contact end 1221 to a direction perpendicular to the plastic shell 121, so that the terminal contact end 1221 will not shift laterally or turn. The guide slot 151 is plate-shaped and is disposed on the slider. Through the slider, the slide rail, and the driving structure, the guide slot 151 can move closer to or away from the plastic shell contouring structure 12 and the concentric limiting structure 13 to achieve directional limiting of the inserted terminal contact end.

[0067] In this embodiment, the guide groove 151 is shaped like a trumpet, a V-groove, or a conical hole. When the terminal is inserted, its contact end first enters the opening side of the guide groove (with a larger lateral dimension or conical hole diameter), and slides along the opening side or conical surface to the bottom side of the guide groove (with a smaller lateral dimension or conical hole diameter). Since the bottom side of the guide groove and the contact end of the terminal are in clearance fit, the terminal is automatically guided, effectively correcting the horizontal offset of the terminal and ensuring that the terminal enters the concentric limiting structure in the correct posture, avoiding insertion failure or terminal damage due to misalignment.

[0068] Example 2:

[0069] As shown in Figure 7, a high-precision multi-terminal automatic shell insertion device of the present invention includes: a frame 2, at least one high-precision terminal shell positioning fixture 1 as described in Embodiment 1, a lifting drive mechanism, and at least one crimping module 4.

[0070] The frame 2 has a worktable. At least one high-precision terminal housing positioning fixture 1 is disposed on the worktable. A lifting drive mechanism is connected to the lifting device 14 of the positioning fixture 1 and is used to drive the lifting device 14 to move up and down. At least one crimping module 4 is disposed above at least one positioning fixture 1, and the crimping module 4 includes a pressing block 41.

[0071] Furthermore, the insertion device also includes at least one servo slide 3, which is mounted on the worktable. The base 11 is set on the servo slide 3. At least one servo slide 3 is driven independently and configured to run synchronously or alternately to drive the positioning fixture 1 to reciprocate along a straight line.

[0072] In this embodiment, the high-precision multi-terminal automatic shell insertion equipment includes a crimping station and a loading station, located at opposite ends of the servo slide 3. The loading station is located on the outer side of the frame. After the equipment starts production and crimping is completed, the servo slide 3 drives the positioning fixture to move to the exposed side of the outer side of the frame 2 to complete manual loading and unloading. The crimping station is located on the inner side of the frame 2 so that the crimping module 4 crimps the precisely positioned terminals and plastic shells, avoiding terminal crimping problems and operator safety issues caused by accidental contact during operation.

[0073] The high-precision multi-terminal automatic shell insertion equipment adopts a purely mechanical structure drive. Specifically, the servo slide 3 is a purely mechanical structure, driven by a servo motor to achieve linear forward and backward movement, used to move the fixture in and out of the pressing station and the loading station to complete the loading and unloading. The servo slide 3 has no external wiring harness or pneumatic pipelines; all power and control lines are arranged on the fixed side of the frame, completely avoiding wear, pulling, abrasion, and aging failures caused by the reciprocating movement of the slide. The two sets of slides are independent of each other, enabling a parallel operation mode of loading at one station and pressing at the other, improving production efficiency.

[0074] The lifting drive mechanism used to drive the lifting device to rise and fall is a purely mechanical transmission mechanism, preferably a cam transmission mechanism. It includes a power source, a track and a cam follower. The cam follower is connected to the lifting device in the positioning fixture. The rotation of the cam shaft drives the cam follower to move according to a preset timing sequence, thereby driving the lifting device to rise and fall.

[0075] Each crimping station is equipped with a crimping module 4, which consists of a servo motor and an integral crimping block 41. The bottom of the crimping block 41 has multiple support grooves, and it is horizontally positioned. The support grooves match the contour of the terminal neck 1222, allowing simultaneous support of all terminal necks 1222. When the positioning fixture 1 is driven by the servo slide 3 to move to the crimping station, i.e., below the crimping module 4, the lifting member 141 always supports the terminal necks 1222 at the same horizontal height. The terminal contact end 1221 is elastic; after the crimping block 41 presses down, the terminal contact end 1221 engages in the support groove, with the bottom of the support groove supporting the terminal neck 1222, maintaining the terminal necks 1222 at the same horizontal height. Subsequently, the lifting member 141 is driven downwards, completely disengaging from the terminal 122. Finally, the crimping block 41 presses down to complete the crimping of the terminal 122 and the plastic shell 121. During operation, the servo motor precisely controls the downward stroke and pressure. After pressing down to the desired position, it can hold the pressure for a short time to ensure that the terminal is firmly crimped. Furthermore, the pressure block only moves in a linear motion up and down and does not interfere with the purely mechanical mechanisms such as the servo slide below and the lifting drive mechanism.

[0076] Furthermore, the insertion device also includes at least one sliding drive mechanism, which is slidably engaged with the contact end limiting structure 15 to drive the contact end limiting structure 15 to slide closer to or away from the terminal contact end 1221.

[0077] Preferably, the high-precision multi-terminal automatic shell insertion equipment is configured as a dual-station system, with each station independently driven and configured to operate synchronously or alternately. Each station includes a servo slide 3, a positioning fixture 1, a pressing module 4, a lifting drive mechanism, and a sliding drive mechanism. Two independent servo slides are symmetrically arranged on the machine frame's worktable, forming a dual-station operating structure. Each servo slide 3 is equipped with a positioning fixture 1 and is matched with a lifting drive mechanism and a sliding drive mechanism. A pressing module 4 is also provided at the pressing station of the servo slide 3. The two sets of servo slides are independently driven and configured to operate synchronously or alternately, enabling parallel operations where one fixture performs material loading while the other performs pressing. The system consists of two sets of servo slides, two sets of positioning fixtures, and two sets of pressing modules, with at least one servo slide working alternately or simultaneously without interference.

[0078] Example 3:

[0079] This embodiment describes a high-precision multi-terminal automatic shell insertion method, which includes:

[0080] S1: Position the plastic shell, insert the terminal into the terminal socket of the plastic shell, and guide the terminal axially once to keep the terminal and the terminal socket of the plastic shell coaxial;

[0081] S2: Push the terminal to the same height;

[0082] S3: Perform secondary circumferential guidance on the terminals to align them circumferentially with the terminal sockets of the plastic housing;

[0083] S4: Pre-press the terminals to keep the terminal necks at the same height, then release the push on the terminals;

[0084] S5: Final pressure is applied to the terminals to complete the synchronous insertion of multiple terminals into the housing;

[0085] S6: Remove the plastic shell with the inserted terminal.

[0086] Specifically, in step S1, the plastic shell is positioned by the plastic shell contouring structure 12.

[0087] Specifically, in step S1, the axial guidance is achieved through the guide channel of the concentric limiting part 131. After the lower part of the terminal passes through the plastic shell, it enters the guide channel, and the guide channel axially guides the terminal that has passed through.

[0088] Specifically, in step S2, the lifting device 14 pushes the terminal to keep the terminal at the same height.

[0089] Specifically, in step S3, the secondary circumferential guidance is achieved by the guide slot 151 of the contact end limiting structure 15 cooperating with the terminal contact end 1221 to correct the circumferential orientation of the terminal and align the terminal with the terminal socket of the plastic shell in the circumferential direction.

[0090] Specifically, in step S4, the terminals are pre-pressed by pressing down the crimping module 4 so that the neck of each terminal is held by the crimping module 4, and then the lifting device is driven to disengage from the terminals.

[0091] Specifically, in step S5, the terminals are pressed down further by the crimping module 4 to complete the multi-terminal synchronous insertion.

[0092] In this embodiment, "pre-pressing" refers to the crimping module applying a first pressure to hold the terminal neck in place; at this point, the terminal has not yet been pressed into the final position of the plastic shell. "Final pressing" refers to the crimping module applying a second pressure to fully press the terminal into the terminal socket of the plastic shell, completing the final positioning of the terminal. The first and second pressures are determined based on the terminal structure and the crimping process.

[0093] This embodiment describes a specific high-precision multi-terminal automatic shell insertion continuous production process. This production process adopts dual-station continuous production, and the production steps include:

[0094] Step 1: The equipment is started, and the high-precision multi-terminal automatic shell insertion equipment enters the dual-station cycle mode. The servo slide 3 in the first station moves out of the crimping station of the frame 2 and moves to the loading station, where the plastic shell 121 and the terminal 122 are loaded manually.

[0095] During the feeding process of terminal 122, plastic shell 121 is inserted into plastic shell conformal structure 12. Terminal 122 is concentrically guided by concentric limiting part 131 into terminal insertion hole 1211 of plastic shell 121. Concentric limiting part 131 guides the terminal crimping end 1223 axially and radially. The guiding terminal crimping end 1223 and the terminal insertion hole 1211 of plastic shell 121 are located on the same central axis, thereby realizing the primary guidance of the terminal.

[0096] Subsequently, the drive mechanism drives the lifting member 141 to move upward to support the terminal. The terminal neck 1222 is supported by the lifting member 141 to the same height, thereby achieving a fixed height of the terminal and eliminating the height difference between the terminals.

[0097] The contact end limiting structure 15 is driven by the sliding drive mechanism to approach the terminal contact end 1221, so that the terminal contact end 1221 slides into the guide slot 151 and is clearance-fitted, so that the terminal 122 is kept in a position circumferentially aligned with the terminal socket 1211 of the plastic shell 121, thereby realizing the secondary guidance of the terminal.

[0098] Step 2: After the material is loaded, the servo slide 3 of the first station moves into the frame 2 and transports the positioning fixture 1 to the pressing station.

[0099] Step 3: The servo motor of the crimping module 4 in the first station presses down the pressing block 41 once. The pressing block 41 supports the terminal neck 1222. The lifting component 141 is driven down by the lifting drive mechanism to completely detach from the terminal 122. Then the pressing block 41 presses down a second time to complete the synchronous insertion of multiple terminals. At this time, the servo slide 3 in the second station synchronously performs the loading operation of step one, and the two stations work in parallel.

[0100] Step 4: The servo slide 3 in the first station moves out of the frame 2 to discharge the material. After the material discharge is completed in the first station, the servo slide 3 is reset. The second station synchronously executes the pressing steps in steps 2 and 3. The first station enters the next round of operation cycle.

[0101] Thus, the first and second workstations complete the alternating feeding and pressing processes without interfering with each other. The entire process relies on a purely mechanical structure to drive the lifting components, ensuring smooth and trouble-free operation. Furthermore, the purely mechanical structure also forms the basis for realizing multi-station processing.

[0102] In this method, the pressure block completes two pressing processes. During the first pressing process, the pressure block presses down to accurately support the terminal based on the positioning fixture pre-positioning the terminal. During the further pressing process, the terminal is crimped to the plastic shell.

[0103] 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 high-precision multi-terminal insertion housing positioning fixture, used to position multiple terminals within a plastic housing, characterized in that, include: Base; A plastic shell conforming structure is disposed on the base, and the plastic shell conforming structure is provided with a conforming through groove to accommodate a plastic shell with terminal sockets; A concentric limiting structure is disposed between the plastic shell conforming structure and the base. The concentric limiting structure is provided with a plurality of concentric limiting parts, and the plurality of concentric limiting parts correspond one-to-one with the terminal socket of the plastic shell and are coaxially arranged. A lifting device is disposed below the base. The lifting device includes multiple lifting components, which can pass through the base and correspond one-to-one with the multiple concentric limiting parts. as well as A contact end limiting structure is slidably disposed on one side of the concentric limiting structure, and the contact end limiting structure is configured to limit the contact end of the terminal.

2. The high-precision multi-terminal insertion housing positioning fixture according to claim 1, characterized in that, Each of the multiple concentric limiting parts has a guide channel, which is coaxially arranged with the terminal socket of the plastic shell. The guide channel is configured to keep the terminal and the terminal socket of the plastic shell coaxial.

3. The high-precision multi-terminal insertion housing positioning fixture according to claim 2, characterized in that, The lifting member has a pushing state and a disengaging state. In the pushing state, the lifting member is configured to push the terminal inserted into the guide channel to the same horizontal height. In the disengaging state, the lifting member is configured to disengage from the terminal after crimping.

4. The high-precision multi-terminal insertion housing positioning fixture according to claim 1, characterized in that, The base has a through hole for the lifting component to pass through, and the contoured through groove of the plastic shell contouring structure matches the outer contour of the plastic shell.

5. The high-precision multi-terminal insertion housing positioning fixture according to claim 1, characterized in that, The contact end limiting structure has a guide groove, which is parallel to the central axis of the terminal insertion hole of the plastic shell and corresponds one-to-one with the terminal insertion hole. It is configured such that after the terminal is inserted into the plastic shell, it slides toward the terminal to limit the contact end of the terminal.

6. The high-precision multi-terminal insertion housing positioning fixture according to claim 5, characterized in that, The length of the guide slot is greater than the lifting stroke of the lifting component.

7. The high-precision multi-terminal insertion housing positioning fixture according to claim 5, characterized in that, The lateral dimension of the guide slot opening side is greater than the lateral dimension of the guide slot bottom side, and the guide slot and the terminal contact end form a clearance fit.

8. A high-precision multi-terminal automatic shell insertion device, characterized in that, The insertion device includes: The frame has a worktable. At least one high-precision multi-terminal insert positioning fixture according to any one of claims 1-7 is disposed on the worktable. A lifting drive mechanism, which is connected to the lifting device of the positioning fixture, is used to drive the lifting device to move up and down. At least one crimping module is disposed above the at least one positioning fixture, and the crimping module includes a crimping block.

9. The high-precision multi-terminal automatic shell insertion device according to claim 8, characterized in that, The insertion device also includes at least one servo slide, which is mounted on the worktable. Each servo slide is driven independently and configured to run synchronously or alternately to drive the positioning fixture to reciprocate along a straight line.

10. The high-precision multi-terminal automatic shell insertion device according to claim 8, characterized in that, The insertion device further includes at least one sliding drive mechanism, which slides in cooperation with the contact end limiting structure to drive the contact end limiting structure to slide closer to or away from the terminal contact end.

11. A high-precision multi-terminal automatic shell insertion method, characterized in that, The method includes: S1: Position the plastic shell, insert the terminal into the terminal socket of the plastic shell, and guide the terminal axially once to keep the terminal and the terminal socket of the plastic shell coaxial; S2: Push the terminal to the same height; S3: Perform secondary circumferential guidance on the terminals to align them circumferentially with the terminal sockets of the plastic housing; S4: Pre-press the terminals to keep the terminal necks at the same height, then release the push on the terminals; S5: Final pressure is applied to the terminals to complete the synchronous insertion of multiple terminals into the housing; S6: Remove the plastic shell with the inserted terminal.

12. The high-precision multi-terminal automatic shell insertion method according to claim 11, characterized in that, In step S1, the plastic shell is positioned by the plastic shell contouring structure; the primary axial guidance is achieved by the guide channel of the concentric limiting part, and the lower part of the terminal enters the guide channel after passing through the plastic shell, and the guide channel axially guides the terminal that passes through.

13. The high-precision multi-terminal automatic shell insertion method according to claim 11, characterized in that, In step S2, the terminals are pushed up by the lifting device to keep them at the same height.

14. The high-precision multi-terminal automatic shell insertion method according to claim 11, characterized in that, In step S3, the secondary circumferential guidance is achieved by the guide groove of the contact end limiting structure cooperating with the terminal contact end to correct the circumferential orientation of the terminal and align the terminal with the terminal socket of the plastic shell in the circumferential direction.

15. The high-precision multi-terminal automatic shell insertion method according to claim 11, characterized in that, In step S4, the terminals are pre-pressed by pressing down the crimping module so that the neck of each terminal is held by the crimping module, and then the lifting device is driven to disengage from the terminals.

16. The high-precision multi-terminal automatic shell insertion method according to claim 11, characterized in that, In step S5, the terminals are pressed down further by the crimping module to complete the synchronous insertion of multiple terminals into the housing.

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