Automated Wire Heading Device with Eccentric Retention
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Solution Overview
Problem
Existing devices for automatic heading of electrical wiring with insulation displacement (IDC) connectors lack the ability to efficiently handle free leads of recovered wires, leading to manual intervention, increased time and costs, low quality, and reduced productivity due to limited adaptability and configurability.
Innovation Solution
A device with a rotating unit and pressurized retention system using eccentric elements with elastic adaptation for precise locking of wires, allowing for automated heading of free leads before connection, with multiple heading stations for various terminations and configurations, including crimped terminals, sleeves, and tinning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual intervention is used for heading free leads of recovered wires, then flexibility and adaptability are maintained, but time consumption increases and productivity decreases
Solution Approach 1:
The device segments the heading process into distinct modular stations (stripping station, heading station, tinning station, etc.), allowing each function to be independently optimized while maintaining overall system flexibility. This enables automated processing of multiple wire types and heading configurations without requiring complete manual intervention.
Solution Approach 2:
The device employs dynamic elements including a rotating head that can position wires at different angles, adjustable pressing elements that adapt to various wire diameters, and a programmable control system that dynamically configures the heading process parameters. This dynamic adaptability replaces manual flexibility while maintaining productivity.
2Adaptability or versatility
If manual heading of free leads is performed after crimping, then various heading configurations can be achieved, but error risk increases and quality consistency decreases
Solution Approach 1:
The device performs self-service through automated wire feeding, positioning, stripping, heading, and tinning operations. The programmable control system automatically configures the process parameters based on the selected wire type and desired heading configuration, eliminating manual intervention errors while maintaining full configurability for different wire specifications.
Solution Approach 2:
The device incorporates feedback mechanisms including sensors that detect wire position, diameter, and heading formation quality. This feedback is fed back to the control system which automatically adjusts process parameters to maintain consistent quality across different heading configurations, preventing errors before they occur.
3Productivity
If automated wire loading and transfer is used, then productivity increases, but the ability to handle wires requiring non-IDC heading is limited
Solution Approach 1:
The device achieves universality by integrating multiple heading capabilities into a single automated system. The rotating head with multiple positioning stations can accommodate IDC connectors, crimped terminals, sleeves, and other heading types. The programmable control system allows the same wire feeding and transfer mechanism to handle different wire types and heading configurations, making the device versatile while maintaining high productivity.
4Adaptability or versatility
If multiple heading stations are added to provide complete discretionality on terminals, then adaptability improves, but device complexity increases
Solution Approach 1:
The device segments the heading functionality into modular, interchangeable stations that can be independently configured. Each station handles a specific heading operation (stripping, heading, tinning, etc.), and the modular design allows these segments to be arranged in different sequences or configurations based on the required discretionality, managing complexity through functional decomposition.
Solution Approach 2:
The device manages complexity by changing operational parameters (rotation position, pressing force, heating temperature, timing sequences) rather than adding physically complex mechanisms. The programmable control system adjusts these parameters to achieve different heading configurations, providing complete discretionality through software control rather than mechanical complexity.
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 precise and automated handling of free wire ends, reducing errors and increasing productivity by allowing for independent or coordinated operation with existing devices, accommodating wires of different lengths and diameters, and improving the quality of the final product.
Implementation Method 1
This adaption can be advantageously done by elastic elements that act on the periphery of the profile of such eccentric elements
Data Source
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AI summary
This invention concerns a device (1) to complete electrical wiring connectors with insulation piercing both sides, in which is requested in the same wiring a series of cables, which on the one hand, in place of the connector insulation piercing there is a terminal crimped, with further opportunity to meet the request of isolation devices (cover sockets, rubber, tin).