Automated Wire Kitting System for Connector Assembly
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Solution Overview
Problem
Conventional wire kitting systems for assembling wired connectors are costly and time-consuming, often resulting in low first-time quality and increased costs due to manual or robotic assembly inefficiencies.
Innovation Solution
An automated wire kitting system comprising a plurality of terminal containers, transport systems, and a crimp press with a shuttle system and wedge mechanism, which enables robotic preparation and crimping of wire leads with multiple terminal types, and a wire lead singulation system for efficient assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual or robotic assembly is used for wire leads, then flexibility in assembly is maintained, but assembly time and costs increase
Solution Approach 1:
The patent applies preliminary action by pre-assembling wire leads into kits before the actual connector assembly process. Wire leads are prepared in advance with terminals already attached and organized in predetermined arrangements, eliminating the need for time-consuming assembly operations during final connector production. This pre-preparation significantly reduces assembly time while maintaining production flexibility.
Solution Approach 2:
The patent segments the wire assembly process into distinct phases: wire preparation, terminal attachment, and final connector assembly. By dividing the complex assembly task into smaller, pre-completed units (wire leads in kits), the system achieves higher productivity in the final assembly stage without sacrificing overall flexibility.
2Reliability
If conventional wire kitting systems are used, then wire leads can be assembled, but first-time quality is low and rework costs increase
Solution Approach 1:
The patent implements feedback mechanisms through automated optical inspection systems that verify wire lead assembly quality in real-time. Sensors detect positioning accuracy and terminal attachment quality, providing immediate feedback that allows for corrections before final assembly. This ensures high first-time quality while maintaining efficient automated production rates.
Solution Approach 2:
The patent replaces manual mechanical assembly with automated robotic systems that provide consistent, precise positioning and attachment. This substitution eliminates human variability and error, improving first-time quality while maintaining or increasing assembly efficiency through automated processes.
3Adaptability or versatility
If human assemblers search through containers to identify target wire leads, then flexibility in handling different wire types is maintained, but assembly time and training requirements increase
Solution Approach 1:
The patent uses optical scanning and imaging systems to create digital representations of wire leads and their positions within kits. This copying approach allows the automated system to identify and locate specific wire leads without human visual search, eliminating the need for operators to memorize wire configurations while maintaining the ability to handle diverse wire types through programmable recognition.
Solution Approach 2:
The patent implements a universal automated assembly system that can handle multiple wire lead types and configurations through programmable control. The same robotic system and inspection equipment can adapt to different wire types by loading appropriate program data, providing versatility without requiring operator expertise or extensive training for each wire type.
Data Source
AI summary
An automated wire kitting system for assembling wire leads for a wired connector comprises a terminal delivery system configured to obtain a target terminal from a plurality of different types of terminals for wire leads and a crimp press comprising a plurality of dies and being configured to obtain a wire having an exposed portion where the wire's insulation has been removed, receive the target terminal from the terminal delivery system, engage a target die of the plurality of dies corresponding to a type of the target terminal, and crimp the target terminal onto the exposed portion of the wire using the target die of the plurality of dies to assemble a wire lead.