Connector Contact Stacking and TPA Assembly in One Machine
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Solution Overview
Problem
Existing electrical connector assembly processes are costly and complex due to the need for multiple machines to handle various housing geometries, fork contact configurations, and terminal position assurance (TPA) devices, making it difficult to assemble power connectors efficiently and reliably.
Innovation Solution
A connector processing machine with integrated contact loading, stacking, and TPA insertion modules, featuring a platform with feeding mechanisms, punch mechanisms, and manipulators to automate the assembly of contacts and housings, enabling efficient stacking and insertion of contacts into connector housings with TPA devices.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple different machines are provided for each type of power connector with various housing geometries, fork contact configurations, and TPA devices, then assembly reliability is improved, but device complexity and cost increase
Solution Approach 1:
The patent describes a single connector assembly machine capable of assembling multiple types of power connectors with different housing geometries, fork contact configurations, and TPA device variations. The machine achieves universality through programmable control systems that can adapt to different connector types, eliminating the need for multiple dedicated machines while maintaining assembly reliability
Solution Approach 2:
The machine employs dynamic and adjustable components including reconfigurable contact stacking mechanisms, adjustable housing positioning systems, and programmable robotic manipulators that can adapt their configuration based on the specific connector type being assembled. This dynamic adaptability allows one machine to handle multiple connector variants reliably
2Manufacturing precision
If multiple different machines are provided for each type of power connector, then assembly precision is improved, but productivity decreases
Solution Approach 1:
The patent integrates multiple assembly functions into a single machine including contact stacking, housing assembly, TPA device installation, and quality inspection. By merging these functions that would traditionally require separate machines, the system maintains precision while improving productivity through continuous operation and reduced transfer time between machines
Solution Approach 2:
The machine is designed to perform assembly operations continuously without interruption between different connector types. The programmable control system enables seamless transitions between different assembly sequences, maintaining continuous productive action while ensuring precision through controlled, programmed movements rather than manual reconfiguration
3Manufacturing precision
If traditional assembly methods with multiple machines are used, then contact alignment accuracy is improved, but loss of time increases
Solution Approach 1:
The machine performs preliminary positioning and alignment of contacts and housings using programmable robotic manipulators with precision control. Alignment fixtures and positioning mechanisms are pre-configured through software, eliminating the time-consuming manual setup and adjustment required when transitioning between connector types on traditional multiple-machine systems
Solution Approach 2:
The patent replaces manual mechanical alignment processes with automated optical sensing systems and programmable robotic manipulators. These systems use sensors and control algorithms to achieve precise contact alignment automatically, eliminating the time loss associated with manual measurement and adjustment while maintaining or improving alignment accuracy
Data Source
AI summary
A connector processing machine includes a contact feeding mechanism at a contact loading station having a dereeler configured to support a contact reel having a strip of contacts and a feed device configured to feed the contacts from the contact loading station to a contact stacking station. The connector processing machine includes a contact stacking module at a contact stacking station having a contact punch mechanism with a contact cutter configured to successively shear the contacts from the contact strip and a contact inserter mechanism with a contact pusher configured to successively move the sheared contact into a contact nest where the contacts are stacked into a contact stack. The connector processing machine includes a contact manipulator configured to pick the contact stack from the contact nest and place the contact stack into a connector housing.