Insulator Combining Apparatus with Mechanical Detection
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Solution Overview
Problem
Existing insulator-combining apparatuses for assembling connectors in wiring harnesses face issues with correctly detecting the sequence of insulators, leading to potential misalignment due to aging or changes in setup, which affects the quality and efficiency of the assembly process.
Innovation Solution
The apparatus includes holders with identification parts and a nipping mechanism that prevents incorrect insulators from being attached, using a sliding member and restricting means to ensure correct alignment, allowing only correctly identified insulators to be laminated, thereby ensuring accurate sequence detection and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If an electrical detecting jig with switch pin is used to detect insulator attachment, then the detection process is automated, but the detection accuracy deteriorates due to aging and setup variations causing false readings
Solution Approach 1:
The patent replaces the electrical detection system (switch pin making electrical contact) with a mechanical detection system. The detecting jig mechanically engages with the insulator's positioning features (such as ribs or grooves) to physically verify correct placement. This mechanical engagement is not susceptible to electrical aging, contact wear, or setup variations that affect electrical switches, thereby maintaining detection accuracy while preserving automation.
Solution Approach 2:
The insulator itself provides the detection feature through its own structural elements (positioning ribs, grooves, or geometric features). The detecting jig simply reads these self-provided features without requiring external power sources or complex electrical circuits. The insulator's geometry serves as its own identification and verification mechanism, eliminating the need for electrical components that degrade over time.
2Productivity
If holders are allowed to approach freely for insulator lamination, then the assembly process is simple and fast, but the manufacturing precision deteriorates due to potential misalignment of insulators
Solution Approach 1:
The holders are pre-positioned at fixed, predetermined locations before the insulators are attached. The detecting jig verifies that each insulator is correctly placed on its designated holder in the proper sequence. This preliminary positioning and verification ensure that when the holders approach each other for lamination, the insulators are already aligned correctly, maintaining manufacturing precision while enabling rapid automated assembly.
Solution Approach 2:
The detecting jig acts as an intermediary between the holder positioning system and the lamination process. It mediates by verifying insulator placement before allowing the holders to approach, ensuring that only correctly positioned insulators proceed to assembly. This intermediary verification step prevents misalignment without requiring complex real-time control during the approaching motion.
Data Source
AI summary
An insulator-combining apparatus which can correctly detects whether or not insulators are lined up in a predetermined sequence is provided. The plate-combining apparatus includes a plate-setting jig which includes a frame, holder, combining part and erroneous attaching-preventing part. The holders hold insulating plates and are provided being spaced from each other and supported by the frame capable of approaching and leaving each other. The combining part includes a pair of nipping members which positions the holder therebetween so as to cause the holders to approach each other. The erroneous attaching-preventing part prevents the holders from approaching each other when an incorrect insulating plate is attached on the holder.