Contact Loading Assembly for Continuous Connector Strip Feeding
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Solution Overview
Problem
Conventional machines for manufacturing electrical connectors are time-consuming and expensive, requiring significant changes to produce different types of connectors due to their design limitations.
Innovation Solution
An electrical connector assembling machine that uses a continuous extruded dielectric material for connector housings and continuous wires to efficiently manufacture connectors with a feed-based process, incorporating a connector strip feed unit, contact loading assembly, and forming dies to create tapered contacts, allowing for rapid production and easy adaptation to various connector configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional machines are used to manufacture electrical connectors individually, then manufacturing precision can be maintained, but production time and cost increase significantly
Solution Approach 1:
The patent implements a continuous feed process where connector strips and wires are fed continuously through the machine without interruption. The connector strip feed unit advances the strip through the forming area, while the wire feed unit simultaneously feeds wires through forming dies, enabling continuous manufacturing without stopping for individual component handling or assembly operations
Solution Approach 2:
The patent performs preliminary actions by pre-forming tapered ends on wires before insertion into the connector housing. The forming dies shape the wire ends into tapered contacts in advance, and the wire cutter pre-cuts the wires to the required length before the connector assembly process begins, streamlining the overall manufacturing workflow
2Adaptability or versatility
If conventional machines are designed for one particular electrical connector arrangement, then manufacturing precision for that specific connector is maintained, but adaptability to different connector types decreases and requires time-consuming component replacement
Solution Approach 1:
The patent implements dynamic adjustability in the machine components. The wire feed unit can be repositioned along the connector strip feed track to accommodate different wire positions for various connector types. The forming dies can be adjusted or replaced to create different contact configurations, allowing the machine to adapt to multiple connector arrangements without complete disassembly or complex reconfiguration
Solution Approach 2:
The patent designs the machine with universal components that can handle multiple connector types. The connector strip feed unit and wire feed unit are configured to work together in a standardized manner that can accommodate different connector geometries by adjusting feed positions and forming die configurations, enabling one machine to manufacture various electrical connector types through a common manufacturing platform
Data Source
AI summary
An electrical connector assembling machine includes a connector strip feed unit including a feeding device configured to index the connector strip through a feed track in successive feed strokes and a contact loading assembly loading contacts into the connector strip. The contact loading assembly includes a wire distribution unit and a wire feed unit having a feeding device configured to simultaneously index wires through feed tracks in successive feed strokes. The wire feed unit includes a wire guide assembly guiding the wires through the wire feed unit. The contact loading assembly includes a contact forming unit and a contact loading device loading the contacts made from the wires into the connector strip as the connector strip is advanced through the electrical connector assembling machine.