Hybrid Wiring Production with Parallel Feeding and Crimping
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Solution Overview
Problem
Existing machines for producing hybrid electrical wiring structures with both crimp and IDC connectors have limited production rates due to serial processing cycles, leading to inefficiencies and increased production times.
Innovation Solution
A method and machine that optimize processing cycles by allowing simultaneous feeding and crimping operations for two electrical wires, using a holder comb to transfer wires between stations while one is being crimped, and collecting the next wire for crimping, thereby reducing waiting times and increasing productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If wires are processed in serial order (one wire at a time through feeding, crimping, and IDC stations), then the machine structure remains simple, but the production speed is limited and cycle time increases
Solution Approach 1:
The machine is divided into multiple working stations (feeding station, crimping station, IDC connection station) arranged in parallel along a circular path. The holder comb is segmented to accommodate multiple wires simultaneously, with each wire being processed independently through the same sequence of stations, enabling parallel processing of multiple wires to increase production speed
Solution Approach 2:
The holder comb rotates periodically through the working stations in a continuous circular motion. Wires are fed, crimped, and connected to IDC terminals in a rhythmic sequence as the comb passes through each station during its rotation, allowing continuous processing without idle time between operations
2Loss of time
If all wires are loaded onto the holder comb before processing, then feeding operations are simplified, but waiting time increases while crimping operations are performed in sequence
Solution Approach 1:
The holder comb continuously rotates through all working stations without stopping, ensuring that feeding, crimping, and IDC connection operations occur continuously in parallel. Multiple wires are processed simultaneously through different stations at the same time, eliminating idle waiting periods and maximizing productivity
Solution Approach 2:
Wires are pre-loaded onto the holder comb at the feeding station before the crimping and IDC operations begin. This preliminary feeding action allows the subsequent crimping and connection operations to proceed without interruption, reducing waiting time and improving overall production efficiency
Data Source
Figure 1
Figure 2
Figure 3A~3D
AI summary
The present invention refers to a method and a machine for producing hybrid electrical wiring comprising electrical wires terminated by Insulating Displacement Connection connectors and by crimp connectors. Said method and said machine optimize standard processing cycles because, during the time while an electrical wire is being crimped at the crimping station, another electrical wire is collected at the first feeding station and transferred to the crimping station. In this way, it is not necessary to wait that all the wires to be processed are loaded in a series at the first feeding station and that then all the wires are crimped in a series at the crimping station, but the feeding and crimping operations are performed substantially simultaneously for two successively fed wires.