Terminal Reel Cart for Wire Processing Changeovers

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Solution Overview

Problem

In wire processing systems, frequent changes of terminal applicators require downtime as operators must mount and feed terminal strips through the applicator, leading to inefficiencies and increased downtime.

Innovation Solution

A terminal reel cart with caster wheels, a support shaft, and a mounting plate for terminal applicators, allowing the entire unit to be moved with pre-installed terminal strips, and a pivotally mounted guide to facilitate easy installation and removal of the applicator, along with a paper take-up reel and clutch assembly for managing paper backing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the terminal applicator is removed and reinstalled with a new terminal strip, then the wire processing system can use different terminals, but the machine downtime increases due to the threading process

Engineering Contradiction:

Improveability to use different terminalsVSAvoidmachine downtime

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The terminal strip is pre-installed on the terminal reel cart before being brought to the wire processing system. This preliminary action eliminates the time-consuming threading process during changeover, as the applicator is already loaded and ready for immediate use.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system is divided into separate functional units: the terminal reel cart (containing the terminal strip supply) and the wire processing system. This segmentation allows the terminal cart to be independently prepared and moved, enabling quick changeovers without disrupting the main processing system.

Inventive Principle:

Principle #1Segmentation

2Adaptability or versatility

If multiple terminal applicators are kept in stock, then different terminals can be quickly switched, but the space requirements and inventory complexity increase

Engineering Contradiction:

Improveability to switch between applicatorsVSAvoidspace for storing applicators

Core Design Contradiction:

Adaptability or versatilityVSArea of stationary object

Solution Approach 1:

The terminal reel cart is designed as a universal platform that can accommodate different terminal strips and applicator types. Instead of storing multiple complete applicator assemblies, the system uses a single multi-functional cart that can be quickly reconfigured with different terminal strips as needed.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The terminal strip supply function is extracted from the wire processing system and placed on a separate mobile reel cart. This extraction eliminates the need to store multiple applicators at the processing station, as the cart can be brought with the required terminal strip already installed.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of operation

If the terminal reel is mounted directly to the machine, then the terminal strip can be fed through the applicator, but the changeover process becomes more complex and time-consuming

Engineering Contradiction:

Improveterminal strip feedingVSAvoidmounting and threading process

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The terminal reel, terminal strip, and applicator are merged into a single integrated unit on the mobile reel cart. This combination simplifies the changeover process by allowing the entire terminal supply system to be moved as one unit and connected to the wire processing system through a simple interface.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mobile reel cart acts as an intermediary between the terminal strip supply and the wire processing system. It provides a simplified connection interface that eliminates the need for complex mounting and threading operations, requiring only the engagement of the cart with the system.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

Enables quick and efficient changeovers of terminal applicators without the need to re-thread terminal strips, reducing downtime and improving operational efficiency by allowing the terminal reel cart to be moved as a single unit to the wire processing system.

Implementation Method 1

the mounting plate includes a magnetic holder to magnetically hold a terminal applicator in place

Methodology Applied

Scientific EffectMagnetic force: Magnetism

Implementation Method 2

the drive wheel of the terminal reel cart frictionally engages a drive wheel coupled to a drive motor of the wire processing system. The frictional interaction between the drive wheel of the wire processing system and the drive wheel of the terminal reel cart allows the wire processing system to control the operation of the paper take up reel

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS8176626B2Terminal reel cart

Publication Date: 2012.05.15 ARTOS ENG

AI summary

A terminal reel cart that supports a reel of terminals and a terminal applicator such that the terminal applicator can be loaded with the strip of terminals and moved into position relative to a wire processing system. The terminal reel cart supports the reel of terminals and a terminal applicator. The reel cart includes a plurality of wheels that allow the cart to be easily moved throughout a processing facility. The reel cart includes a paper take up reel that is driven by a motor and collects the paper backing from the strip of terminals. The paper take up reel is driven by a drive motor on the wire processing system.