Automated Plug Connection Device with Guide Elements
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Solution Overview
Problem
Existing methods for automating the plug connection of cables with plugs are inefficient and costly, particularly for special plugs and sockets, and are not suitable for cables with plugs at both ends or of varying lengths.
Innovation Solution
A device comprising multiple grippers and handling units with programmable control, allowing for the automated production of plug connections on cables with plugs at one or both ends, using multi-axis robots and surface portals to handle and position the plugs and cables accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a robot with a gripper is used to insert the plug with a search movement, then the plug connection can be automated, but the mechanical stress on the plug and socket increases and the process becomes time-consuming
Solution Approach 1:
A guide device with guide elements is introduced as an intermediary between the robot and the plug/socket connection. The guide elements receive the plug in a receiving area and guide it into the plug counterpart, enabling automated insertion without direct robotic manipulation that causes mechanical stress.
Solution Approach 2:
The plug insertion process is divided into separate functional zones: a receiving area for initial plug placement, a guide area with guide elements for directional guidance, and a final insertion point. This segmentation allows each zone to perform its specific function without subjecting the plug and socket to excessive stress.
2Manufacturing precision
If a guide device with guide elements is used to receive and guide the plug, then the plug can be guided accurately into the plug counterpart, but the device complexity increases
Solution Approach 1:
The guide elements are designed to replicate the geometric characteristics of the plug and its mating socket. By copying the essential geometric features, the guide device provides accurate positioning and guidance without requiring complex active control systems or multiple adjustment mechanisms.
3Reliability
If the plug is pushed into the plug counterpart by an actuator, then the plug connection is established reliably, but the force application must be precisely controlled to avoid damage
Solution Approach 1:
The guide device is designed with cushioning elements that absorb and distribute the insertion forces before they reach the delicate plug and socket contacts. This beforehand cushioning protects the electrical components from damage while the actuator provides the necessary pushing force for reliable connection.
Data Source
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AI summary
The present invention discloses a device for the automated production of a plug connection between a plug arranged on a cable and a mating plug element, particularly for wiring battery modules, especially in the manufacture of vehicles with hybrid and/or electric drive, comprising: a first gripper for gripping the plug, a handling unit with multiple axes for moving the first gripper, wherein the first gripper is in particular a multi-axis robot and/or a gantry, and a controller for controlling the first gripper and the handling unit. The device is provided to include at least one second gripper for gripping the cable or a second plug arranged at the other end of the cable.