Robotic Wire Termination With Pin Alignment and Solder Heating
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Solution Overview
Problem
Conventional wire termination systems for electrical connectors are labor-intensive, time-consuming, prone to errors, and costly due to the manual process of connecting numerous fine wires to connector pins, especially in the medical industry where small wires and many connections are common, leading to defects and increased rework.
Innovation Solution
A robotic wire termination system that includes a housing, an electrical connector alignment plate, a robotic positioner with a heating device, and a control unit with a display for automated wire connection, allowing for precise positioning and heating of solder to connect wires to connector pins, reducing human error and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual wire connection process is used, then flexibility and simplicity are maintained, but labor intensity and error rate increase significantly
Solution Approach 1:
The patent replaces the manual mechanical wire connection process with an automated robotic system that uses computer vision for wire identification and automated positioning mechanisms for precise connector pin alignment, thereby maintaining operational simplicity while dramatically improving productivity
Solution Approach 2:
The robotic system performs self-positioning and self-alignment through automated vision guidance and mechanical feedback mechanisms, eliminating the need for manual intervention while maintaining the flexibility to handle various wire configurations
2Device complexity
If manual wire connection process is used, then device simplicity is maintained, but error rate approaches 25%
Solution Approach 1:
The patent incorporates computer vision systems and sensors that provide real-time feedback on wire position, connector pin alignment, and soldering quality, enabling the robotic system to detect and correct positioning errors before they result in connection defects
Solution Approach 2:
The system performs preliminary wire identification, positioning, and alignment verification using vision systems before the actual connection process, ensuring that all components are correctly positioned to prevent errors during the connection operation
3Device complexity
If manual soldering process is used, then equipment simplicity is maintained, but time consumption and cost increase
Solution Approach 1:
The patent replaces manual soldering operations with an automated robotic soldering system that precisely controls heating parameters, solder application, and cooling processes, dramatically reducing connection time while maintaining equipment simplicity through integrated automated components
4Ease of operation
If manual wire connection is used for fine wires, then operational flexibility is maintained, but material waste increases due to errors
Solution Approach 1:
The robotic system uses vision feedback and positioning sensors to precisely track and control the handling of fine wires throughout the connection process, detecting and correcting positioning errors before they result in wire damage or material waste
Solution Approach 2:
The patent replaces manual handling of fine wires with automated robotic manipulators that provide precise, consistent control over wire positioning and manipulation, eliminating the variability and physical stress associated with manual handling that leads to wire damage
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
The robotic system significantly reduces human error, increases efficiency, and minimizes material waste by automating the wire connection process, ensuring accurate and reliable connections even with small wires and numerous connector pins.
Implementation Method 1
heating device, allowing for precise positioning and heating of solder to connect wires to connector pins
Data Source
AI summary
A robotic wire termination system for efficiently and accurately connecting a plurality of wires to an electrical connector having a plurality of connector pins with corresponding wire receptacles. The system generally includes a housing, a removable alignment plate, a robotic positioner, a heating device, a touch responsive display, and a control unit. The alignment plate removably holds a selected electrical connector in a specific position and orientation with the connector pins exposed in the housing and the wire receptacles exposed outside. The display provides a visual representation of the connector pins and selections of the connector pins. The control unit receives inputs indicating the pin selections and controls the robotic positioner to sequentially move the heating device along three orthogonal longitudinal axes to a series of heating positions relative to the selected connector pins to provide heat for melting solder to connect wires to the wire receptacles.