Vibrating Pallet for Automated Wire Insertion Alignment
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Solution Overview
Problem
Automated wire insertion machines experience high failure rates due to misalignments and interference fits between wire contacts and connectors, caused by tolerance stack-ups and friction, leading to inefficient production processes.
Innovation Solution
A wire insertion system that employs vibratory motion using a vibrating element connected to the gripper, grommet, or fixture, allowing cavities to shift position and break static friction, enabling precise alignment and reducing insertion failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If rigid threaded fixtures are used to attach connectors to the pallet, then the connector position is fixed, but tolerance stack-up causes misalignment between connector cavity locations and programmed positions
Solution Approach 1:
The system transitions from a static rigid fixture to a dynamic vibration-based system. The vibrating element causes the grommet and cavity to oscillate during insertion, enabling the system to adapt to position variations and tolerance stack-up while maintaining precise alignment.
Solution Approach 2:
A vibrating element is introduced to create mechanical vibration in the grommet and cavity assembly. This vibration breaks static friction and allows the cavity to shift position dynamically, accommodating tolerance variations and achieving proper alignment with the wire contact.
2Strength
If the grommet is an interference fit with the wire contact, then the connection is secure, but high friction causes insertion failures and difficulty in seating the contact
Solution Approach 1:
The vibrating element applies mechanical vibration to the grommet and wire contact assembly during insertion. This vibration temporarily reduces the friction between the interference fit surfaces, allowing the wire contact to be seated successfully while maintaining the secure connection once inserted.
Solution Approach 2:
The system applies periodic vibration during the insertion process rather than continuous vibration. The periodic action coincides with the insertion motion, providing friction reduction at critical moments while maintaining connection security after insertion.
3Manufacturing precision
If multiple retry attempts are programmed for failed insertions, then alignment can be corrected, but production time increases due to multiple attempts
Solution Approach 1:
The vibrating element is activated before and during the insertion attempt, preparing the grommet and cavity for alignment. This preliminary vibration action prevents insertion failures before they occur, eliminating the need for multiple retry attempts and maintaining high production speed.
Solution Approach 2:
The system converts the potential harm of friction and misalignment into a benefit by using vibration to break static friction and enable cavity shifting. This transforms the insertion process from a high-failure-risk operation to a reliable single-attempt process.
4Ease of operation
If the wire is less rigid than the contact, then the wire is easier to handle, but fully seating the wire in the connector becomes difficult
Solution Approach 1:
The vibrating element applies vibration to the wire and contact assembly during the seating process. This vibration helps the more flexible wire contact navigate the final seating position in the rigid dielectric cavity, achieving precise alignment and full insertion while maintaining ease of handling.
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 vibratory motion reduces wire insertion failure rates, optimizes production time, and minimizes the need for retries, improving the efficiency and accuracy of the wire insertion process.
Implementation Method 1
A wire insertion system employs vibratory motion using a vibrating element connected to the gripper, grommet, or fixture, allowing cavities to shift position and break static friction
Data Source
AI summary
An apparatus is provided relating to the insertion of one or more wires into a cavity of a fixture of a structure or component. The wire insertion apparatus includes a grommet, a gripper adapted to interface with the grommet, and at least a first vibrating element. The first vibrating element is connected to and vibrates one or more of the apparatus, the grommet, the gripper, the wire, and/or a component of the apparatus. Vibration, induced in any direction, enables the cavities to shift position during insertion relative to the contact, thus increasing the tolerance of the cavity, reducing the failure rate of wire insertion, and reducing total production time. The vibration breaks the static friction of the contact in the grommet or dielectric opening, creates the positive locating required to insert the contact in the grommet and/or dielectric, and/or pivots the contact.