Robotic Wire Termination for Accurate Multi-Pin Connector Soldering
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for connecting wires to electrical connectors are labor-intensive, time-consuming, prone to errors, and costly, especially with the increasing complexity of connector pins in medical devices, leading to high error rates and material waste.
Innovation Solution
A robotic wire termination system with a housing, alignment plate, robotic positioner, heating device, and control unit that automates the connection process by visually guiding operators and independently controlling the heating device to melt solder at specific connector pins, reducing human error and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual wire connection and soldering is performed by technicians, then flexibility and adaptability are maintained, but labor intensity, time consumption, and error rates increase significantly
Solution Approach 1:
The patent replaces the manual mechanical system of wire positioning and soldering with an automated robotic system. The robotic positioner mechanically positions wires and applies solder without human intervention, substituting manual dexterity with programmed mechanical precision. This resolves the contradiction by maintaining operational capability through automation while dramatically improving connection speed and reducing labor intensity.
Solution Approach 2:
The system enables self-service automation where the robotic positioner independently performs wire positioning, solder application, and cleaning functions without continuous human intervention. The visual guidance system provides real-time feedback to operators, allowing the system to guide its own operation while reducing manual labor. This maintains operational flexibility while improving productivity.
2Adaptability or versatility
If manual wire connection and soldering is performed by technicians, then adaptability to different connectors is maintained, but error rates approach 25% and rework time increases
Solution Approach 1:
The patent incorporates a visual guidance system that provides real-time feedback to operators and the robotic system. The system displays visual indicators showing wire positions, connector pin locations, and soldering status, enabling both automated and manual operations to verify connections accurately. This feedback mechanism dramatically reduces error rates while maintaining adaptability to different connector types through programmable configurations.
Solution Approach 2:
The robotic positioner replaces manual wire positioning and soldering with automated mechanical precision. The system uses programmed motion control to position wires and apply solder with consistent accuracy across different connector types. This substitution maintains versatility through software configuration while eliminating human error, achieving both adaptability and high reliability.
3Quantity of substance
If the number of connector pins increases to accommodate more wires, then connection capability improves, but the complexity of manual identification and connection increases
Solution Approach 1:
The robotic positioner replaces manual identification and positioning with automated vision-guided mechanical positioning. The system can handle high-density connectors with numerous pins by using programmed motion paths and visual feedback to identify and connect each wire-pin pair accurately. This substitution allows the system to manage complex, high-pin-count connectors without increasing operational complexity, maintaining connection capability while reducing the effective complexity through automation.
Solution Approach 2:
The visual guidance system acts as an intermediary between the operator/robotic system and the complex connector. It provides visual mapping and real-time feedback that simplifies the interaction with high-density connectors, translating complex spatial relationships into intuitive visual information. This intermediary layer enables accurate connection of numerous pins while reducing the perceived complexity for operators and the control system.
4Productivity
If automated robotic positioning is implemented, then connection speed and accuracy improve, but system complexity and initial cost increase
Solution Approach 1:
The patent divides the wire termination system into modular functional components: a robotic positioner for wire handling, a separate heating device for soldering, and an independent visual guidance system. This segmentation allows each component to be optimized independently and facilitates easier maintenance and operation. The modular architecture reduces overall system complexity while maintaining high connection speed and accuracy through coordinated operation of specialized subsystems.
Solution Approach 2:
The robotic positioner is designed with multi-functionality, capable of performing wire positioning, solder application, and cleaning functions. The visual guidance system also serves multiple purposes: guiding automated operation, assisting manual operation, and providing verification feedback. This universality reduces the number of separate devices needed, simplifying the overall system while maintaining high productivity through a single integrated robotic platform.
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 system significantly reduces human error and labor costs while enhancing the accuracy and speed of wire connections, particularly for complex connectors with numerous pins, by using a robotic positioner and visual guidance.
Implementation Method 1
position the heating device in a first heating position relative to the first connector pin to melt solder in a corresponding first wire receptacle
Implementation Method 2
heat the solder with the soldering device to melt the solder on both the fine wire and the connector pin
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.