Connector Housing Pre-Insertion Structure for Automated Terminal Assembly
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Solution Overview
Problem
Manual assembly of connectors is labor-intensive and time-consuming, making it costly and inefficient for large-scale production.
Innovation Solution
A connector and housing design featuring limiting protrusions, crimping portions, and release arms that facilitate automated assembly by allowing terminals to be pre-inserted and crimped within the housing, enabling automatic crimping and assembly processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly is used to insert terminals into housing, then assembly precision can be controlled, but assembly time and labor cost increase significantly
Solution Approach 1:
The terminal is pre-inserted into the housing with the limiting protrusion temporarily retaining it in a partial insertion state. This preliminary positioning allows automated equipment to perform crimping operations without requiring manual precision insertion, thereby increasing assembly speed while maintaining precision through the limiting protrusion's geometric constraints
Solution Approach 2:
The limiting protrusion on the terminal automatically engages with the housing wall to retain the terminal in the pre-inserted state without requiring additional retention mechanisms. The terminal's own structure provides the retention function, enabling automated handling and positioning during the assembly process
2Extent of automation
If terminals are fully inserted directly without pre-insertion, then assembly process is simplified, but automated crimping cannot be performed
Solution Approach 1:
The insertion process is divided into two distinct stages: pre-insertion where the terminal is partially inserted and retained by the limiting protrusion for crimping operations, and final insertion where the terminal is fully inserted after crimping. This segmentation enables automated crimping by creating an intermediate state that accommodates automated equipment access while maintaining a relatively simple overall assembly process
Solution Approach 2:
The limiting protrusion serves as an intermediary mechanism that enables the transition from manual to automated assembly. It temporarily holds the terminal in a pre-inserted state, allowing automated crimping equipment to perform operations, and then facilitates the final insertion. This intermediary structure bridges the gap between simplified insertion and automated crimping requirements
Data Source
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AI summary
A connector (100, 200) and a connector housing (2, 4) are disclosed. The connector includes: a housing (2, 4) in which a receiving passage (25, 45) is formed; and a terminal (1, 3) inserted in an insertion direction and mounted in the receiving passage. At least one limiting protrusion (22, 42) is arranged on a wall of the receiving passage, and is configured to be abutted against the terminal so as to retain a portion of the terminal outside the receiving passage when the terminal is pre-inserted into the receiving passage.