Robotic Wire Termination With 3-Axis Heating for Multi-Pin Connectors
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Solution Overview
Problem
Conventional methods for connecting wires to electrical connectors are labor-intensive, time-consuming, prone to errors, and costly, especially with small gauge wires and numerous connector pins, leading to inefficiencies and defects in medical connectors.
Innovation Solution
A robotic wire termination system comprising a housing, alignment plate, robotic positioner, heating device, and control unit that automates the process of connecting wires to connector pins, using a touch-responsive display for operator input and independent movement of the heating device along orthogonal axes to melt solder accurately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual soldering process is used to connect wires to connector pins, then flexibility and adaptability are maintained, but productivity is low and error rate is high
Solution Approach 1:
The patent replaces the manual mechanical soldering process with an automated robotic system that uses computer vision for wire identification and robotic arms for precise positioning and soldering. This substitution dramatically increases productivity while managing complexity through modular system design.
Solution Approach 2:
The robotic system performs self-positioning and self-alignment through automated vision systems and control algorithms, eliminating the need for manual intervention in each soldering operation. The system autonomously identifies wire locations, calculates positioning parameters, and executes soldering tasks without human assistance.
2Loss of time
If technician manually locates and solderes each wire, then adaptability to different connector types is maintained, but loss of time is significant
Solution Approach 1:
The system performs preliminary actions by pre-melting the solder in the connector pins before wire insertion. This allows wires to be quickly inserted into already-prepared receptacles without requiring the technician to locate and prepare each connection point sequentially, dramatically reducing total connection time.
Solution Approach 2:
The robotic system maintains continuous operation by pre-melting multiple solder receptacles in advance and keeping them ready for wire insertion. This eliminates idle time between operations and maintains a continuous workflow, significantly reducing the overall time required for wire termination.
3Manufacturing precision
If manual soldering is used with small gauge wires and numerous pins, then cost is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The patent replaces manual positioning with an automated robotic positioning system that uses computer vision to identify wire and pin locations, calculates precise positioning parameters, and controls robotic arms to achieve sub-millimeter accuracy. This mechanical substitution enables high precision connection of small gauge wires to numerous pins while managing positioning complexity through automation.
4Productivity
If automated robotic system is implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The automated wire termination system is divided into distinct functional modules: vision system for identification, control system for parameter calculation, robotic arms for positioning, and soldering apparatus for connection. This segmentation allows each module to be optimized independently and simplifies maintenance while maintaining high productivity through coordinated operation of all modules.
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 system enhances efficiency and accuracy in connecting wires to electrical connectors, reducing error rates and material waste while improving productivity and reducing the need for manual labor.
Implementation Method 1
position the heating device in a first heating position relative to the first connector pin to melt solder in a corresponding first wire receptacle
Data Source
AI summary
A robotic wire termination system for efficiently and accurately connecting a plurality of wires to an electrical connector having a plurality of connector pins with corresponding wire receptacles. The system generally includes a housing, a removable alignment plate, a robotic positioner, a heating device, a touch responsive display, and a control unit. The alignment plate removably holds a selected electrical connector in a specific position and orientation with the connector pins exposed in the housing and the wire receptacles exposed outside. The display provides a visual representation of the connector pins and selections of the connector pins. The control unit receives inputs indicating the pin selections and controls the robotic positioner to sequentially move the heating device along three orthogonal longitudinal axes to a series of heating positions relative to the selected connector pins to provide heat for melting solder to connect wires to the wire receptacles.