Terminal Insertion Device with Parallel Joint Mechanism
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Solution Overview
Problem
Conventional terminal insertion devices face challenges in reducing terminal insertion errors and failures due to the need to grasp both terminals and wires simultaneously, leading to a heavy insertion head and increased cycle time, as well as issues with wire flexibility causing inclination and roll direction problems during insertion.
Innovation Solution
A terminal insertion device equipped with a parallel joint mechanism, biaxial sensors, and roll angle compensation controls that measure and adjust the terminal's inclination and position independently, allowing for accurate alignment and insertion without grasping the terminal, thereby reducing the weight and complexity of the mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insertion head grasps both the terminal and the electric wire simultaneously, then the terminal can be inserted into the connector housing, but the insertion head becomes heavy and the number of components increases
Solution Approach 1:
The grasping function is segmented into two separate units: a first grasping unit that holds the terminal and a second grasping unit that holds the electric wire. This segmentation allows each unit to be optimized independently, reducing the overall complexity and weight while maintaining reliable terminal insertion capability.
2Reliability
If the insertion head grasps both the terminal and the electric wire simultaneously, then the terminal can be inserted into the connector housing, but the movement speed of the mechanism decreases and the work time increases
Solution Approach 1:
The parallel joint mechanism provides dynamic control of the first and second grasping units, enabling independent movement and positioning. This dynamic capability allows the system to optimize movement speed while maintaining accurate terminal insertion, improving both productivity and reliability simultaneously.
3Weight of moving object
If only the electric wire part slightly away from the terminal is grasped without grasping the terminal, then the insertion head weight is reduced, but the electric wire inclination causes the terminal to be inserted in the wrong direction
Solution Approach 1:
A measurement unit measures the position of the terminal, and this measurement information is fed back to the control unit. The control unit uses this feedback to adjust the parallel joint mechanism, compensating for electric wire inclination and ensuring accurate terminal insertion even when only the electric wire is grasped by the second grasping unit.
4Measurement precision
If a camera is provided on the insertion head to measure position shift, then position measurement can be performed, but the device complexity and cost increase
Solution Approach 1:
A mark is attached to the terminal as an intermediary reference object. The measurement unit measures the position of this mark instead of directly measuring the terminal itself. This intermediary approach simplifies the measurement system compared to using a camera, while still achieving accurate position measurement for terminal insertion.
Data Source
AI summary
A terminal insertion device that inserts a terminal into a connector housing, is provided with a stationary disk, a parallel joint mechanism which grasps an electric wire which is connected to the terminal at a leading end and conveys the electric wire and inserts the terminal into a cavity of the connector housing, a biaxial sensor portion capable of measuring at least a contour position of the terminal, roll angle calculation portion which calculates a roll angle with respect to a reference condition, and a roll angle compensation control portion that controls the parallel joint mechanism to compensate an inclination of the terminal.