Terminal Insertion Alignment for Tilted Wire End Terminals
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Solution Overview
Problem
Conventional terminal insertion units face difficulties in smoothly inserting end portion terminals into connector housings due to the need for strict position management, which burdens operators.
Innovation Solution
A terminal insertion unit and method utilizing housing pallets, tilt correction, and positional deviation correction mechanisms to ensure smooth insertion of electric wire terminals into connector cavities, including a first transporting portion, tilt correction portion, and terminal insertion portion to correct tilting and positional deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the connector housing is moved up, down, left, and right during insertion, then the end portion terminal can be smoothly inserted, but strict position management is required before insertion which burdens the operator
Solution Approach 1:
Instead of moving the connector housing to align with the terminal, the invention moves the terminal itself to align with the cavity. The transporting portion grips the electric wire and moves the terminal in the insertion direction, while the tilt correction portion adjusts the terminal's orientation. This inversion of the moving element simplifies position management by directly positioning the terminal at the cavity entrance before insertion begins.
Solution Approach 2:
The invention performs preliminary alignment actions before the actual insertion process. The transporting portion pre-positions the terminal at the cavity entrance, and the tilt correction portion pre-adjusts the terminal's orientation to match the cavity's insertion axis. These preliminary actions eliminate the need for complex real-time position management during insertion, reducing operator burden.
2Manufacturing precision
If the end portion terminal is inserted in a tilting state, then insertion may be difficult, but correcting the tilt requires additional position management
Solution Approach 1:
The tilt correction portion introduces dynamic adjustment capability to the system. It can tilt around the insertion axis in response to detected tilt angles, enabling real-time correction of terminal orientation. This dynamic adjustment automatically adapts to tilting conditions without requiring manual position management, maintaining alignment precision while reducing operational complexity.
Solution Approach 2:
The tilt correction portion detects the tilt angle of the terminal around the insertion axis and uses this feedback information to automatically adjust the terminal's orientation. The detection result drives the tilt correction mechanism, creating a closed-loop control system that maintains proper alignment without operator intervention for position management.
3Manufacturing precision
If manual position management is performed, then insertion accuracy can be maintained, but operator burden increases
Solution Approach 1:
The system performs self-alignment and self-correction operations automatically. The transporting portion self-adjusts to bring the terminal to the cavity entrance, and the tilt correction portion self-corrects any tilting based on detected angles. This self-service capability maintains high insertion accuracy while completely eliminating the need for manual position management by operators.
Solution Approach 2:
The invention replaces manual mechanical position management with automated mechanical systems. The transporting portion and tilt correction portion use automated mechanisms (gripping, transporting, and tilting mechanisms) to achieve precise positioning and alignment, substituting operator actions with automated device functions that maintain accuracy without increasing operator burden.
Data Source
AI summary
It is provided to suppress a burden of an operator and smoothly insert an end portion terminal of an electric wire with terminal into a cavity of a connector housing. A terminal insertion unit includes a housing pallet, a first transporting portion, a tilt correction portion configured to receive the electric wire with terminal from the first transporting portion and detect and correct the tilting, a second transporting portion transporting the electric wire with terminal after tilting correction, and a terminal insertion portion configured to receive the electric wire with terminal from the second transporting portion, detect and correct a positional deviation between a front-end position of the end portion terminal and a position of a cavity as an insertion target while inserting the end portion terminal after positional deviation correction into the cavity as the insertion target.