Wire Terminal Crimping with Automated Optical Positioning

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Solution Overview

Problem

The existing terminal crimping devices require complex adjustments and labor-intensive operations when switching between different types of terminal metal fittings, leading to reduced productivity and quality, especially when crimping various kinds of fittings.

Innovation Solution

A terminal crimping device equipped with a position adjusting mechanism controlled by a photographing device, a multiapplicator for selecting the appropriate anvil and crimper pair, and a height adjusting mechanism, which allows for accurate positioning and adjustment of terminal metal fittings to the crimping position, reducing labor and improving efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If a multi-crimping device with multiple anvil and crimper pairs is used to handle various terminal metal fittings, then the device can accommodate different fitting types, but the complexity of adjusting and positioning each fitting type increases significantly

Engineering Contradiction:

Improveability to handle various terminal metal fittingsVSAvoidcomplexity of adjustment operation

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent implements a universal terminal supply mechanism that can accommodate multiple types of terminal metal fittings through a single standardized interface. The terminal holder and supply mechanism are designed to universally hold and supply different fitting types without requiring separate supply devices for each type, thereby reducing device complexity while maintaining versatility.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent replaces manual mechanical adjustment operations with an automated image processing system. A camera captures images of the terminal fittings, and image processing automatically determines their positions and orientations, eliminating the need for complex manual adjustment mechanisms and reducing device complexity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If manual adjustment operations are performed to position terminal metal fittings accurately at the crimping position, then positioning accuracy can be achieved, but labor time and productivity are reduced

Engineering Contradiction:

Improvepositioning accuracy of terminal metal fittingVSAvoidproductivity in crimping process

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent replaces manual mechanical positioning with an automated optical measurement system. A camera captures images of the terminal fittings, and image processing algorithms automatically calculate their positions and orientations relative to the crimping position, achieving high positioning accuracy without manual intervention and thereby improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-positioning of terminal metal fittings through automated image capture and processing. The image processing unit automatically determines the correct positioning based on captured images, allowing the system to self-adjust without external manual operation, thus improving both accuracy and productivity.

Inventive Principle:

Principle #25Self-service

3Reliability

If separate supply devices are provided for each type of terminal metal fitting, then accurate supply of specific fittings is ensured, but the device complexity and space requirements increase

Engineering Contradiction:

Improveaccuracy of terminal metal fitting supplyVSAvoidnumber of supply devices

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a universal terminal supply mechanism that can supply multiple types of terminal metal fittings through a single standardized interface. The terminal holder is designed to accommodate different fitting types while maintaining consistent supply accuracy, thereby eliminating the need for multiple separate supply devices and reducing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges multiple separate supply devices into a single integrated terminal supply mechanism. By combining the functionality of multiple devices into one unified system with a common terminal holder and supply path, the patent maintains reliable supply accuracy while reducing the overall number of devices and simplifying the system structure.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10978846B2Wire terminal crimping method

Publication Date: 2021.04.13 YAZAKI CORP

AI summary

A terminal crimping device crimps a terminal metal fitting positioned at a crimping position to an electric wire. The device includes an anvil which is positioned under the crimping position, a crimper which is positioned above the crimping position, a pressing mechanism which presses down the crimper to crimp the terminal metal fitting to the electric wire with the anvil and the crimper, a terminal supply mechanism to supply the terminal metal fitting to the crimping position, a position adjusting mechanism which is provided in the terminal supply mechanism to adjust a position of the terminal metal fitting for the crimping position, and a photographing device to photograph the terminal metal fitting fed to the crimping position.