Wiring Harness Terminal Insertion Using Independent Dual Chucks
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Solution Overview
Problem
The existing manufacturing apparatus for wiring harnesses requires rearrangement of wires, leading to increased processing areas and costs, as well as potential wire entanglement and inefficiencies in terminal insertion due to the need for wire holder bars and complex chucking mechanisms.
Innovation Solution
A manufacturing apparatus with a pair of independent terminal inserting heads that pick up and insert both ends of the wire with terminals simultaneously into connector housings, eliminating the need for wire holder bars and allowing for efficient terminal insertion without rearrangement, using a transferring device and chucking units that move freely to minimize processing areas and prevent entanglement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If wires are rearranged on a wire holder bar to enable terminal insertion, then terminal insertion can be performed, but processing area increases and cost increases due to requiring wire holder bars and carts
Solution Approach 1:
The invention extracts and eliminates the wire holder bar from the system. Instead of placing wires on a holder bar and then inserting terminals, the terminal inserting head directly picks up wires from the transferring device and performs insertion, removing the intermediate holder bar component entirely
Solution Approach 2:
The terminal inserting head is designed to perform multiple functions: it acts as both the picking-up mechanism and the insertion mechanism. This multi-functional design eliminates the need for separate wire holder bars and reduces the number of components required in the system
2Productivity
If wires are placed to intersect on the wire chuck bar for terminal insertion, then terminal insertion can be performed, but wires become easily entangled and may fall out
Solution Approach 1:
The invention removes the wire chuck bar from the system entirely. The terminal inserting head directly interacts with wires on the transferring device without using an intermediate chuck bar, eliminating the entanglement problem associated with intersecting wire placement
Solution Approach 2:
The terminal inserting head is divided into independent right and left chucks that can operate separately. Each chuck independently picks up and inserts terminals, allowing wires to be processed in an orderly fashion without intersecting paths that would cause entanglement
3Reliability
If a single terminal inserting chuck is used to avoid interference, then wire entanglement is prevented, but terminal insertion time increases
Solution Approach 1:
The terminal inserting head is segmented into independent right and left chucks that can operate simultaneously. Each chuck handles one end of a wire independently, allowing parallel terminal insertion operations that reduce total insertion time while maintaining wire handling stability
Solution Approach 2:
The right and left chucks are designed to move independently with flexible positioning capabilities. This dynamic design allows the chucks to coordinate their movements to prevent wire interference while performing simultaneous insertion operations, optimizing both speed and reliability
Data Source
AI summary
For inserting terminals into each connector housing and reducing working area in processes by eliminating rearrangement of wires with terminals, a manufacturing method for wiring harnesses, including the steps of: picking up both ends of a wire at a predetermined position in a transferring direction from a transferring device by a pair of chucks, each chuck picking up one of the both ends of the wire; chucking the both ends of the wire with terminals fed through the pair of chucks, each end of the wire being fed through one of the pair of chucks, by a pair of terminal inserting heads as the terminal inserting device, the pair of terminal inserting heads moving freely independently of each other at least in a direction of a row of a connector housings; and inserting the terminals at the both ends simultaneously into each of the connector housings.