Center Twisting of Wire Pairs for Gap-Free Automated Insertion
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Solution Overview
Problem
Existing methods for twisting wires are not compatible with automated terminal insertion equipment, as twisted wires are difficult for automated actuators to grip, leading to inefficiencies in assembly and potential electrical performance degradation due to gaps between wires.
Innovation Solution
A method and apparatus that securely grip the central portions of wires in contact, laterally deflect them, and rotate them to twist without gaps, using a U-shaped bladder or jaws to maintain continuous contact and a rotating mechanism to achieve center twisting, allowing for automated insertion and improved electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wire twisting methods are used, then twisted pairs are formed with improved electromagnetic compatibility, but the twisted wires become difficult for automated actuators to grip
Solution Approach 1:
The patent applies preliminary action by securing the wire ends before twisting, and by pre-positioning the wires in a parallel configuration. This allows the twisting operation to be performed on controlled, stationary wire ends rather than attempting to grip and twist free-moving wires, making the process compatible with automated equipment.
Solution Approach 2:
The patent segments the wire handling process into distinct stages: securing the ends, positioning central portions, and then twisting. The gripping mechanism separates the gripping function from the twisting function, allowing automated actuators to grip secured ends while a separate mechanism performs the twisting operation on the central portions.
2Reliability
If wire ends are terminated before twisting, then electrical connections are established, but automated insertion equipment cannot properly handle the twisted wires
Solution Approach 1:
The patent performs the twisting operation after terminal insertion by gripping and rotating the central portions of the wires. This reverses the traditional sequence, allowing automated equipment to first insert terminated wires into connector bodies, and then perform twisting as a subsequent operation on the inserted wires.
Solution Approach 2:
The patent inverts the traditional sequence of operations by performing twisting after terminal insertion rather than before. Instead of twisting then inserting, the method secures ends, inserts terminals, and then twists the central portions, making the process compatible with automated insertion equipment.
3Reliability
If traditional twisting methods are used, then wire pairs are twisted, but gaps may form between wires degrading electrical performance
Solution Approach 1:
The patent applies local quality by having different portions of the wire perform different functions: the ends are secured for stability and terminal attachment, while the central portions are gripped and twisted to form the twisted pair. The gripping mechanism is designed to contact only the central portions, ensuring that twisting occurs in the region where continuous contact is most critical for electrical performance.
Solution Approach 2:
The patent introduces a gripping mechanism as an intermediary between the automated actuator and the wires. This gripping mechanism maintains continuous contact with the central portions of the wires during twisting, ensuring that the wires remain in close proximity and preventing gaps from forming between them.
4Reliability
If manual twisting methods are used, then wire pairs can be twisted, but assembly efficiency is reduced
Solution Approach 1:
The patent applies self-service by designing the gripping mechanism to automatically position and grip the central portions of the wires without requiring manual intervention. The mechanism uses the wire ends themselves as reference points, automatically locating and gripping the central portions at the correct spacing for twisting.
Solution Approach 2:
The patent replaces manual mechanical twisting with an automated gripping and rotating mechanism. The automated actuator drives the gripping mechanism, which in turn rotates the central portions of the wires to form the twisted pair, eliminating the need for manual twisting operations.
Data Source
AI summary
A method of twisting a pair of wires includes the steps of arranging a first wire parallel to a second wire along a longitudinal axis, securing ends of the first and second wires, and gripping outer surfaces of central portions of the first and second wires. The inner surfaces of the central portions of the first and second wires are in contact with one another. The method further includes deflecting central portions of the first and second wires orthogonally from the longitudinal axis and rotating the central portions of the central portions of the first and second wires, thereby twisting the first and second wires about one another.