Automated Lead Insertion Pressing Mechanism for Connector Assembly
Solution Overview
Problem
Manual insertion of leads into a housing in connector manufacturing often results in misalignment and reduced efficiency due to the first lead shifting from its precise position, hindering the insertion of the second lead, which affects soldering quality.
Innovation Solution
An automated assembly system with a fixation device, pressing mechanism, and vision system that holds the first lead in place using a robot and pressing tool, and guides the insertion of both leads to ensure accurate alignment and contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual insertion of leads is performed, then operational flexibility is maintained, but manufacturing precision deteriorates due to lead misalignment
Solution Approach 1:
The patent replaces manual mechanical insertion with an automated pressing mechanism that uses controlled mechanical force to insert leads. The pressing mechanism applies precise downward force through a pressing element to push leads into the housing, eliminating manual handling errors and improving alignment precision while maintaining operational control through automated sequencing.
2Productivity
If first lead is inserted before second lead, then insertion sequence is established, but manufacturing precision deteriorates due to first lead offset during second lead insertion
Solution Approach 1:
The patent applies preliminary anti-action by introducing a pressing mechanism that proactively prevents the first lead from moving during the insertion of the second lead. The pressing element applies continuous downward force on the first lead to counteract any upward movement tendency, thereby maintaining position stability throughout the sequential insertion process.
Solution Approach 2:
The pressing mechanism acts as an intermediary between the two lead insertion operations. It mediates the interaction between the first and second lead insertions by providing stabilizing force to the first lead during the second lead insertion, ensuring both leads are properly positioned without mutual interference.
3Manufacturing precision
If pressing mechanism is added to hold first lead, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The pressing mechanism is designed with multi-functionality to reduce overall system complexity. The same pressing element that applies downward force to hold the first lead also serves as the insertion tool for pushing the lead into the housing. This consolidation of holding and insertion functions into a single mechanism avoids adding separate complex subsystems while maintaining precision.
Data Source
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AI summary
An assembly system, includes: an assembly mechanism comprising a fixation device for fixing a housing and a first lead assembly mechanism and a second lead assembly mechanism provided at both sides of the fixation device, respectively, wherein the first lead assembly mechanism is adapted to insert a first lead into the housing, the second lead assembly mechanism is adapted to insert a second lead into the housing, and the first lead is inserted into the housing before the second lead. The assembly system further comprises a pressing mechanism adapted to hold the first lead inserted into the housing at a correct installation position, so as to prevent the first lead from being offset from its correct installation position and hindering operation of inserting the second lead during inserting the second lead. The assembly system may automatically complete the task of assembling the first lead and the second lead into the housing, improving the efficiency of inserting the leads into the housing, and increasing the quality of the assembly product.