Rotating Wire Insert Fixture for Multi-Connector Harness Assembly
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Solution Overview
Problem
Current wire harness production faces challenges in automating the connection of multiple wires to insulating connectors due to the need for various terminal installation forms and snap-fit structures, which complicates the processing of wires and reduces efficiency.
Innovation Solution
A connector insert device with a terminal fixing portion that rotates and clips wires to a predetermined angle, a transferring portion that stores and conveys wires to a storage area, and an insert portion that automatically inserts the wires into connectors, allowing for flexible adaptation to different wire sizes and terminal angles, utilizing a linear motor for efficient conveying.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple terminal installation forms and snap-fit structures are used to adapt to various insulating connectors, then the adaptability of the wire harness production system is improved, but the device complexity and processing difficulty increase
Solution Approach 1:
The patent applies universality by designing a multi-functional terminal installation device that can handle multiple terminal types and installation forms through a single integrated system. The device includes adjustable clamping mechanisms, rotatable terminal fixing portions, and configurable conveying paths that enable it to adapt to various insulating connector structures without requiring separate specialized equipment for each terminal type.
Solution Approach 2:
The patent implements dynamics through the rotatable terminal fixing portion that can adjust to predetermined angles, and the configurable conveying portion that can be repositioned along the conveying path. These dynamic elements allow the device to adapt its structure and orientation to match different terminal installation requirements, resolving the contradiction between adaptability and complexity by providing flexible adjustment rather than multiple fixed configurations.
2Productivity
If manual processing is used to handle various terminal installation forms, then the device complexity is reduced, but the productivity and automation level decrease
Solution Approach 1:
The patent applies self-service through the automatic wire insertion mechanism where the terminal fixing portion automatically clamps, rotates to the predetermined angle, and releases the terminal into the insulating connector without manual intervention. The conveying portion automatically transports wires through the processing path, and the system coordinates these actions autonomously, achieving high automation while maintaining adaptability through programmable control of the installation sequences.
3Manufacturing precision
If a fixed terminal fixing structure is used, then the manufacturing precision is improved, but the adaptability to different wire sizes and terminal angles decreases
Solution Approach 1:
The patent implements parameter changes through the adjustable clamping force of the terminal fixing portion, the variable rotation angles to predetermined positions, and the reconfigurable conveying portion positions. These adjustable parameters allow the device to maintain precise terminal installation while adapting to different wire diameters, terminal types, and installation angles by programmatically changing the operational parameters rather than altering the physical structure.
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 device enables high automation and production efficiency by allowing automatic wire insertion with set processing sequences and angles, accommodating various wire and terminal configurations, thus enhancing adaptability and productivity.
Implementation Method 1
utilizing a linear motor for efficient conveying
Data Source
AI summary
A connector insert device for automatic switching of connector fixture includes terminal fixing portions clipping a wire, a wire storage portion storing groups of wires, transferring portions configured to store the wire clipped by the terminal fixing portion in the wire storage portion through a conveying portion, a connector fixing portion storing connectors, and an insert portion inserting the groups of wires in the wire storage portion into the connector fixing portion through the conveying portion. Each terminal fixing portion includes a terminal fixing base, a terminal clipping base, and a terminal gripper. The terminal clipping base is rotatably connected with the terminal fixing base through a terminal connecting shaft. The terminal gripper is connected with the terminal clipping base. The terminal fixing portion rotates the wire to a predetermined angle. The transferring portions clip the wire and places the wire in the wire storage portion.