Crimp Contact Orientation and Insertion for Dense Connectors

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Solution Overview

Problem

The process of inserting crimped wires into connectors is labor-intensive due to the small and dense working area, the need for precise orientation, and varying depths of insertion, making automation challenging.

Innovation Solution

An automated system and method that includes automatic orientation and insertion movements to align the crimp contact with the connector's electrical contact surface, utilizing grippers and motors to rotate the crimp contact or connector, and a controlled insertion process to ensure proper alignment and depth.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual insertion method is used, then flexibility and adaptability are maintained, but labor intensity increases and productivity decreases

Engineering Contradiction:

Improveinsertion efficiencyVSAvoidlabor intensity

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The system uses vision sensors to automatically detect wire positions, orientations, and connector hole locations, enabling the machine to self-adjust and perform insertion operations without manual intervention, thereby resolving the contradiction between automation and operational flexibility

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent implements dynamic adjustment mechanisms that allow the system to adapt to varying wire layouts, connector types, and insertion depths through programmable control and real-time sensor feedback, maintaining ease of operation while achieving high productivity

Inventive Principle:

Principle #15Dynamics

2Productivity

If automated insertion system is implemented, then productivity increases, but device complexity increases

Engineering Contradiction:

Improveinsertion efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system employs multi-functional components such as grippers that can both grasp and orient wires, vision sensors that detect multiple parameters simultaneously, and a single robotic manipulator that performs positioning and insertion, reducing overall system complexity while maintaining high productivity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent combines multiple functions into integrated modules: the vision system integrates detection and measurement functions, the robotic arm combines positioning and insertion operations, and the control system unifies coordination of all components, thereby achieving high productivity without excessive complexity

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If precise orientation is required, then manufacturing precision improves, but device complexity increases

Engineering Contradiction:

Improveorientation accuracyVSAvoidalignment mechanism complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The system replaces complex mechanical alignment mechanisms with vision-based detection and software-controlled robotic positioning, using sensors to detect wire orientations and the control system to calculate and execute precise insertion angles, achieving high manufacturing precision with reduced mechanical complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The vision system continuously monitors wire positions and orientations, providing real-time feedback to the control system which adjusts the robotic manipulator's movements accordingly, ensuring precise orientation and insertion depth while maintaining a relatively simple mechanical structure

Inventive Principle:

Principle #23Feedback

4Adaptability or versatility

If varying insertion depths are accommodated, then adaptability improves, but manufacturing precision becomes more difficult to maintain

Engineering Contradiction:

Improvedepth variation capabilityVSAvoidinsertion depth accuracy

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The system uses dynamic control to adjust insertion depths for different wire-connector combinations, with the robotic manipulator programmably varying insertion distance based on real-time detection of connector type and wire configuration, maintaining precision across varying depths through software control rather than fixed mechanical constraints

Inventive Principle:

Principle #15Dynamics

Data Source

PatentUS20260011968A1System and method for crimped-wires insertion to a connector machine

Publication Date: 2026.01.08 FRISIMOS

AI summary

A system and method for automatically inserting crimp contacts of a plurality of wires into holes of a connector is disclosed. Each hole of a connector has an electrical contact surface that is for electrical/physical contact with a designated part of a crimp contact. Thus, for proper electrical/physical contact, the connector and/or the crimp contact may be rotated to prepare for insertion of the crimp contact. As such, prior to the insertion, the connector and/or the crimp contact is rotated in an automatic orientation movement. After which, the automatic insertion movement is performed in which the crimp contact and/or the connector are moved so that the designated part of the crimp contact is in electrical/physical contact with the electrical contact surface of the hole. The automatic insertion movement may include the crimp contact being stationary and the connector is moving, or the connector being stationary and tire crimp contact moving.