System and method for crimped-wires insertion to a connector machine

A method for automatically inserting crimp contacts of a plurality of wires into holes of a connector, the connector having within a plurality of electrical contact surfaces for electrical contact with the crimp contacts of the plurality of wires, the method comprising;

• prior to selecting a respective wire, spreading the plurality of wires;
• for at least two of the plurality of wires, sequentially selecting the respective wire so that a designated part of the crimp contact of the respective wire physically contacts the electrical contact of a respective hole of the connector by:
• prior to performing an automatic insertion movement of one or both the crimp contact of the respective wire or the connector, performing an automatic orientation movement by moving one or both of the crimp contact of the respective wire or the connector in preparation the automatic insertion movement;
• and
• after automatically performing the orientation movement, performing the automatic insertion movement of one or both the crimp contact of the respective wire or the connector by moving one or both of the crimp contact of the respective wire or the connector so that the designated part of the crimp contact physically contacts the electrical contact surface of respective hole of the connector.

A method for automatically inserting crimp contacts of a plurality of wires into holes of a connector, the connector having within a plurality of electrical contact surfaces for electrical contact with the crimp contacts of the plurality of wires, the method comprising;

• for at least two of the plurality of wires, sequentially selecting a respective wire so that a designated part of the crimp contact of the respective wire physically contacts the electrical contact of a respective hole of the connector by:
• prior to performing an automatic insertion movement of one or both the crimp contact of the respective wire or the connector, performing an automatic orientation movement by moving one or both of the crimp contact of the respective wire or the connector in preparation the automatic insertion movement;
• and
• after automatically performing the orientation movement, performing the automatic insertion movement of one or both the crimp contact of the respective wire or the connector by moving one or both of the crimp contact of the respective wire or the connector so that the designated part of the crimp contact physically contacts the electrical contact surface of respective hole of the connector;
• and
• wherein the plurality of electrical contact surfaces in the connector face different directions;
• and
• wherein, for the respective wire, one or both of moving the connector or moving the crimp contact of the respective wire results in movement of one or both of:
• (i) a part of the crimp contact of the respective wire that is for physical contact with the electrical contact surface;
• or (ii) the electrical contact surface, so that the part of the crimp contact and the electrical contact surface are in alignment prior to insertion.

A system for automatically inserting crimp contacts of a plurality of wires into holes of a connector, the connector having within a plurality of electrical contact surfaces for electrical contact with the crimp contacts of the plurality of wires, the system comprising:

• a controller;
• an automatic orientation movement device in communication with the controller and configured to perform an automatic orientation movement by moving one or both of the crimp contact of the respective wire or the connector in preparation for an automatic insertion movement;
• and
• an automatic insertion movement device in communication with the controller and configured to perform the automatic insertion movement of one or both the crimp contact of the respective wire or the connector by moving one or both of the crimp contact of the respective wire or the connector so that a designated part of the crimp contact physically contacts the electrical contact surface of respective hole of the connector;
• wherein the automatic orientation movement device is configured to perform the automatic orientation movement so that orientation of the designated part of the crimp contact and orientation of the electrical contact of a respective hole are the same so that the insertion movement, resulting in the physical contact of the designated part of the crimp contact with the electrical contact surface of the respective hole of the connector, consists of a lateral movement without any axial movement.

A system for automatically inserting crimp contacts of a plurality of wires into holes of a connector, the connector having within a plurality of electrical contact surfaces for electrical contact with the crimp contacts of the plurality of wires, the system comprising:

• an automatic orientation movement device;
• an automatic insertion movement device;
• a controller in communication with the automatic orientation movement device and the automatic insertion movement device, the controller configured to:
• prior to selecting a respective wire, control spreading the plurality of wires;
• for at least two of the plurality of wires, control sequentially selecting the respective wire so that a designated part of the crimp contact of the respective wire physically contacts the electrical contact of a respective hole of the connector by:
• prior to performing an automatic insertion movement of one or both the crimp contact of the respective wire or the connector, control the automatic orientation movement to perform an automatic orientation movement device by moving one or both of the crimp contact of the respective wire or the connector in preparation the automatic insertion movement;
• and
• after automatically performing the orientation movement, control the automatic insertion movement device to perform the automatic insertion movement of one or both the crimp contact of the respective wire or the connector by moving one or both of the crimp contact of the respective wire or the connector so that the designated part of the crimp contact physically contacts the electrical contact surface of respective hole of the connector.