Automated Multi-Wire Crimping for Short Wire Tip Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing crimping machines struggle with crimping multi-wire cables, particularly those with short wire tips, due to limited space and interference from adjacent wires, making it difficult to automate the process without manual intervention.
Innovation Solution
The system employs a combination of robotic manipulation and machine vision to spread wires at angles, position them accurately, and use a pin-like device to manage wire placement, allowing for automated crimping without holding individual wires, thereby overcoming space constraints and interference issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional crimping machines are used for multi-wire cables, then the crimping process can be automated, but adjacent wires interfere with each other and short wire tips cannot be properly positioned
Solution Approach 1:
The system separates wire manipulation from crimping by using a robotic system to individually position each wire tip into the applicator, while the crimping machine handles the crimping operation. This segmentation allows automated crimping while eliminating wire interference issues through precise individual wire control.
Solution Approach 2:
A robotic system acts as an intermediary between the multi-wire cable and the crimping machine. The robot picks up individual wire tips and places them into the applicator, mediating the interaction between adjacent wires and the crimping mechanism, thereby preventing wire interference while maintaining automation.
2Productivity
If multiple wires are crimped simultaneously, then production efficiency increases, but space constraints and wire interference make automation difficult
Solution Approach 1:
The robotic system performs preliminary actions by individually picking and positioning each wire tip into the applicator before crimping. This preliminary wire management simplifies the subsequent crimping operation, enabling efficient automated processing without complex wire handling during the actual crimping phase.
Solution Approach 2:
The patent replaces manual mechanical wire manipulation with a robotic system that uses vision guidance and precise positioning. This substitution eliminates the complexity of mechanical wire management while maintaining high productivity through automated pick-and-place operations followed by crimping.
3Quantity of substance
If wire tips are kept short to maximize space utilization, then more wires can fit in the cable, but manual manipulation becomes necessary for proper positioning
Solution Approach 1:
The machine vision system creates a digital copy or map of the wire locations and characteristics before the robotic system manipulates them. This visual copying enables the automated system to identify and position short wire tips accurately without manual intervention, allowing maximum wire density while maintaining automation.
Solution Approach 2:
The patent replaces manual mechanical manipulation of short wire tips with a robotic system guided by machine vision. The vision system detects wire tip positions and the robot precisely places them into the applicator, enabling automated handling of short wires that would otherwise require manual positioning.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient and automated crimping of multi-wire cables with short wire tips, improving production efficiency by eliminating the need for manual manipulation and accommodating complex cable configurations.
Implementation Method 1
the crimping tool applies a mechanical force in order to deform (e.g., compress and/or reshape) the crimp contact until it is cold-welded onto the wire
Data Source
AI summary
A method and apparatus for automating one or more steps of a crimping process for crimping a crimp contact to a wire of a multi-wire cable is disclosed. Crimping wires is typically a labor-intensive process. As such, some or all of the manual steps may be automated, such as by manipulating one or more of the wires in preparation for inserting the wires into the crimping machine. In this way, the previously manually-operated machine may be less reliant or entirely non-reliant on manual labor.