Connector Wiring Guide Graphics for Accurate Pin Insertion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manual insertion of electrical pins into connectors is a tedious, error-prone process that lacks automation, leading to potential miswires and downstream failures, with current methods offering inadequate assistance for accuracy and requiring significant manual dexterity and concentration.
Innovation Solution
A system that uses a processor to create a wiring guide graphic based on connector body identity, engineering specifications, and wiring tables, generating a visual map to accurately indicate connector cavity locations and wire insertions, thereby reducing human error and enabling automated processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual insertion of electrical pins into connectors is performed by operators, then flexibility and adaptability are maintained, but error rate increases and productivity decreases
Solution Approach 1:
A graphical user interface (GUI) acts as an intermediary between the operator and the connector assembly process. The GUI displays a visual representation of the connector body with cavity locations and wire routing paths, serving as a mediator that guides the operator's actions without replacing manual dexterity. This intermediary provides real-time feedback and guidance, reducing errors while maintaining operator control and flexibility.
Solution Approach 2:
The patent replaces traditional mechanical aids such as physical templates, stencils, or fixtures with a software-based graphical interface system. Instead of using mechanical guides to indicate cavity locations and wire paths, the system uses display technology to present visual information, thereby substituting a mechanical guidance system with an information-based digital system that is more flexible and updatable.
2Manufacturing precision
If manual dexterity and long-term concentration are required for proper pin insertion, then precision can be maintained, but operator fatigue increases and error rate rises
Solution Approach 1:
The system provides self-service guidance by automatically displaying the correct cavity locations, wire routing paths, and insertion sequences without requiring the operator to memorize or interpret complex documentation. The GUI adapts to the specific connector type and wire assembly being installed, providing context-specific instructions that reduce the cognitive load and concentration time required while maintaining precision.
Solution Approach 2:
The system performs preliminary actions by pre-configuring the graphical display with all necessary information about cavity locations, wire paths, and insertion sequences before the operator begins the assembly process. This advance preparation of visual guidance eliminates the need for the operator to concentrate on interpreting instructions during the actual insertion process, reducing mental fatigue while maintaining precision.
3Productivity
If no manufacturing automation exists for connector assembly, then process flexibility is maintained, but productivity remains low and errors are frequent
Solution Approach 1:
The system creates a digital copy or virtual representation of the physical connector body and its cavity structure within the graphical interface. This virtual model accurately replicates the spatial relationships, cavity locations, and wire routing paths of the actual connector, allowing operators to visualize and plan the assembly process without adding physical complexity to the assembly system itself.
Data Source
AI summary
A system for creating a wiring guide graphic comprising a database configured to receive inputs of a connector body identity, an engineering specification and a wiring table; and a processor coupled to the sensor, the processor configured to create a wiring guide graphic.