Terminal Insertion Station

Manual pull check fixtures

Right insertion of terminal in a right cavity is an important process in wiring harness manufacturing. Push the terminal properly inside the right cavity, feel the click sound (terminal latch locking) and pull it back to ensure that perfectly locked inside the connector latch.

Manual Pull check fixtures are being used to perform pull check function once the terminal is inserted inside the cavity. In general, the pull check force is fixed at 4~5 Newton and for fuse box or special size connectors will have 8~10 Newton force.

Manual Pull check fixture are two types

Pull check with feed back
Pull check without feed back

Light guided circuit insertion

Basically, it is a microprocessor controlled a navigation system to guide where to pick? And where to insert. Also pull check is a mandatory function in between each insertion cycle.

Also, multiple variants can be programmed in the system and it can be recalled manually or automatically very quickly to reduce cycle time of the process. There are many features are available based on the system which we select.

Operator log in / Supervisor log in
Cycle time & its data
Good / Bad part produced
Program selection through scan
Reference label print for next process
E-planning (centralized planning)
Work instruction in visualized format

Continuity check based insertion

This method is a prevention control for wrong insertion. While inserting the both ends of terminals inside the cavity the continuity is checked. If it is a single side insertion, an earth point will be provided to touch and confirm the right cavity to insert.

Pull load monitoring

In some connectors pull load force is a key parameter and should not exceed the manufacturer’s recommendation. This is to avoid latch damage while doing pull check. So, we have load cell based solution for pull load monitoring during insertion stage itself. If the pull load exceeds the preset value, system gives alarm and stops operation.

Bend terminal detection –

Flimsy male terminal frequently facing this issue and it is being detected at final continuity checker or at customer place. Now as a prevention method, we are providing terminal bend detection gauge at insertion stage itself.

Manual pull check fixtures

Light guided circuit insertion

Continuity check based insertion

Pull load monitoring

Bend terminal detection –

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