Wire Harness Terminal Stamping System Solution

Integrated drive and control design, high repeat positioning accuracy, uniform and precise stamping

Wire harnesses are key components in automotive circuits that connect various electrical devices, responsible for transmitting communication signals and power between equipment. Terminal crimping is a crucial step in the wire harness manufacturing process.

Industry Background

Wire harnesses are key components in automotive circuits, connecting various electrical devices and transmitting communication signals and power between them. Terminal crimping is a crucial step in the wire harness manufacturing process. Traditional terminal crimping relies on asynchronous motors driving eccentric wheel mechanisms for reciprocating motion to achieve terminal stamping. This method has drawbacks, such as relying entirely on mechanical adjustments for terminal thickness, lacking precise control, and no pressure data feedback during the process, making it difficult to assess terminal quality. These issues can significantly increase quality control costs.

Xinje's wire harness terminal stamping equipment uses a servo control solution, allowing precise control of stamping positions and monitoring terminal forming pressure, which improves the pass rate of terminals and automatically filters out defective products. This enhances production efficiency while significantly reducing management costs.

Control Solution

The wire harness terminal stamping servo machine integrates the process within the servo drive and uses industry-leading procedures. It doesn't require PLC programming, and users can simply call the built-in program to set relevant parameters and begin use immediately.

When Used Individually

It can be paired with the TG series touch screen for convenient function selection, parameter setting, data monitoring, NG (No Good) display, and action triggering. It can also connect external pedals or switches to trigger stamping actions via IO signals.

When Used with Production Lines

It can communicate with an upper computer via RS485 or RS232 for function selection, parameter setting, stamping data monitoring, NG code reading, action triggering, etc. It can also connect to the upper computer's IO interface to trigger stamping actions.

Solution Advantages

Integrated Drive and Control Design

This integrated solution includes built-in terminal stamping processes, eliminating the need for PLC control and programming. It features simple wiring and convenient, quick setup

Eccentric Wheel Motion Calculation

By inputting the maximum stroke of the eccentric mechanism, the mechanical motion trajectory can be calculated, ensuring even downward speed and precise position

Stamping Distance Detection

Detects the lowest achievable position of the mechanical head according to set torque, and automatically calculates the target stamping position based on the input terminal thickness

End Torque Detection for Stamping

Uses torque feedback at the stamping position to identify defects such as unstripped wires, missing wires, or substantial core loss

High Repeat Positioning Accuracy

After extensive repetitive operations, the positioning accuracy at the stamping position remains high and stable.

Multi-step Pressing Function

Allows for single-step task execution, continuous multi-step execution, or segmented multi-step task execution triggered by pulse/communication.