Terminal un-seated tester for smart kitting of wired connectors

Wired connector assembly systems and methods involve fixing a connector in an assembly station and following, by an assembler, a set of instructions indicating a set of wires and a respective set of terminal portions of the connector in which the set of wires are to be seated. A controller of the assembly station then monitors a pulling force on the connector via each seated wire to verify proper wire-terminal portion seating. After completing the set of instructions, including verifying each proper wire-terminal portion seating, the connector is released from the assembly station and a fully assembled wired connector is obtained.

FIELD

The present disclosure generally relates to wired connector assemblies and, more particularly, to systems and methods for assisting an assembler in the assembly of wired connectors.

BACKGROUND

Wired connectors typically comprise a connector defining a plurality of terminal portions where a plurality of respective wires are seated (i.e., physically secured to create an electrical connection). During assembly of wired connectors, an assembler typically employs a “push-click-tug” procedure where each wire is inserted by the assembler into its respective terminal portion until a click indication is observed. After observing this click indication, the assembler then tugs on the wire to ensure it can withstand a certain tension or pulling force. This assembly process typically involves the assembler following a printed diagram or some other static instruction display, which is prone to assembler misinterpretation, particularly for less experienced users. In addition, there is a large amount of variability in the tension or pulling force applied by each assembler during the tug portion of the push-click-tug method, which could result in wires that are improperly seated in the connector. As a result, a large number of wired connectors do not pass testing, leading to decreased first time quality (FTQ) metrics and increased costs to fix improperly assembled wired connectors. Accordingly, while these conventional assembly systems and methods work well for their intended purpose, an opportunity exists for improvement in the relevant art.

SUMMARY

According to one aspect of the present disclosure, an assembly station of an assembly system for assisting an assembler in the assembly of a connector and a set of wires seated in a set of terminal portions of the connector, respectively, is presented. In one exemplary implementation, the assembly station comprises a base member, a latching system attached to the base member, defining a receptacle, and being configured to move between a closed position in which the connector is fixed within the receptacle and an open position in which the connector is removable from the receptacle, a sensor system attached to the base member and being configured to sense a pulling force on the connector while fixed within the receptacle of the latching system, at least a portion of a guide system configured to output instructions, and a controller configured to command the guide system to sequentially output a set of instructions instructing the assembler how to properly seat the set of wires in the set of terminal portions of the connector, during the output of each particular instruction of the set of instructions, monitor, using the sensor system, the sensed pulling force on the connector, in response to the sensed pulling force satisfying a first threshold indicative of a proper wire-terminal portion seating, command the guide system to complete the output of the particular instruction and to then sequentially output any remaining instructions of the set of instructions until the output of a final instruction is complete, including the sensed pulling force again satisfying the first threshold, and a wired connector is thereby obtained.

In some implementations, the controller is configured to, in response to the sensed pulling force exceeding a greater second threshold indicative of a pulling force that could damage the connector, command the latching system to the open position thereby freeing the connector from the receptacle. In some implementations, each instruction of the set of instructions comprises a respective set of visual outputs, and wherein each visual output of the respective set of visual outputs identifies either a particular wire of the set of wires or a particular terminal portion of the connector in which the assembler is to seat the particular wire. In some implementations, the base member defines an opening aligned with the receptacle, wherein the guide system comprises a display device attached to a first side of the base member that opposes a second side of the base member where the latching system and the sensing system are attached, and wherein the display device is aligned with the opening. In some implementations, the display device is configured to output at least some of each respective set of visual outputs through the opening defined by the base member to thereby identify the particular terminal portion of the connector in which the assembler is to seat the particular wire. In some implementations, the guide system further comprises a visual indicator system that is distinct from the assembly station and its display device and that is configured to output at least some of each respective set of visual outputs proximate to a particular container of a set of respective containers that store the set of wires to identify the particular container from which the assembler is to retrieve the particular wire.

In some implementations, the latching system is pneumatically-actuated latch comprising two latching members each movable along an axis and being configured to move inwardly along the axis to fixably contact the connector in the closed position and to move outwardly along the axis to not contact the connector in the open position.

In some implementations, the sensor system comprises at least one pair of force sensors attached to the base member, wherein a first force sensor of each pair of force sensors is attached to the base member proximate to a diagonally opposing corner of the receptacle relative to a second force sensor of the pair of force sensor.

In some implementations the assembly station further comprises a manual release switch that, when actuated, moves the latching system to the open position.

In some implementations, the controller is a programmable logic controller (PLC) and the first and second thresholds are calibratable during a calibration process that utilizes an external handheld tensiometer.

According to another aspect of the present disclosure, an assembly method using an assembly station of an assembly system to assist an assembler in assembling a connector and a set of wires seated in a set of terminal portions of the connector, respectively, is presented. In one exemplary implementation, the assembly method comprises detecting, by a controller of the assembly station, that the connector is fixed by and within a receptacle defined by a latching system of the assembly station, wherein the latching system is attached to a base member of the assembly station and is configured to move between a closed position in which the connector is fixed within the receptacle and an open position in which the connector is removable from the receptacle, in response to detecting that the connector is fixed within the receptacle, commanding, by the controller, a guide system of the assembly system to sequentially output a set of instructions instructing the assembler how to properly seat the set of wires in the set of terminal portions of the connector, during the output of each particular instruction of the set of instructions, monitoring, by the controller and using a sensor system of the assembly station, a sensed pulling force on the connector, wherein the sensor system is also attached to the base member, and in response to the sensed pulling force satisfying a first threshold indicative of a proper wire-terminal portion seating, commanding, by the controller, the guide system to complete the output of the particular instruction and to then sequentially output any remaining instructions of the set of instructions until the output of a final instruction is complete, including the sensed pulling force again satisfying the first threshold, and a wired connector is thereby obtained.

In some implementations, the method further comprises in response to the sensed pulling force exceeding a greater second threshold indicative of a pulling force that could damage the connector, commanding, by the controller, the latching system to the open position thereby freeing the connector from the receptacle. In some implementations, each visual instruction of the set of visual instructions comprises a respective set of visual outputs, and wherein each visual output of the respective set of visual outputs identifies either a particular wire of the set of wires or a particular terminal portion of the connector in which the assembler is to seat the particular wire. In some implementations, the base member defines an opening aligned with the receptacle, wherein the guide system comprises a display device attached to a first side of the base member that opposes a second side of the base member where the latching system and the sensing system are attached, and wherein the display device is aligned with the opening. In some implementations, the display device is configured to output at least some of each respective set of visual outputs through the opening defined by the base member to thereby identify the particular terminal portion of the connector in which the assembler is to seat the particular wire. In some implementations, the guide system further comprises a visual indicator system that is distinct from the assembly station and its display device and that is configured to output at least some of each respective set of visual outputs proximate to a particular container of a set of respective containers that store the set of wires to identify the particular container from which the assembler is to retrieve the particular wire.

In some implementations, the latching system is a pneumatically-actuated latch comprising two latching members each movable along an axis and being configured to move inwardly along the axis to fixably contact the connector in the closed position and to move outwardly along the axis to not contact the connector in the open position, and wherein the assembly station further comprises a manual release switch that, when actuated, moves the latching system to the open position.

In some implementations, the sensor system comprises at least one pair of force sensors attached to the base member, wherein a first force sensor of each pair of force sensors is attached to the base member proximate to a diagonally opposing corner of the receptacle relative to a second force sensor of the pair of force sensors.

In some implementations, the controller is a PLC and the method further comprises calibrating, by the controller, the first and second thresholds are during a calibration process that utilizes an external handheld tensiometer.

According to yet another aspect of the present disclosure, a method for a user to assemble a wired connector is presented. In one exemplary implementation, the method comprises obtaining a set of wires for the wired connector, each wire of the set of wires being stored in a respective container of a set of containers, obtaining a connector for the wired connector, the connector defining a set of terminal portions for seating the set of wires, respectively, fixing the connector with and in a receptacle of a latching system of an assembly station of an assembly system, wherein the latching system is attached to a base member of the assembly station, according to a set of visual instructions each comprising a set of light outputs and being sequentially output by a guide system of the assembly system instructing the user how to properly seat the set of wires in the set of terminal portions of the connector, performing, by the user, a set of push-click-tug procedures each comprising (i) observing for a first light output of a current visual instruction of the set of visual instructions for a current push-click-tug procedure, the first light output indicating a target container of the set of containers and obtaining a target wire therefrom, (ii) after obtaining the target wire, observing for a second light output of the current visual instruction indicating a target terminal portion of the set of terminal portions and pushing the target wire into the target terminal portion, (iii) while pushing the target wire into the target terminal portion, observing for a click indication and, after observing the click indication, tugging on the target wire to cause a pulling force on the connector that is sensed by a sensor system of the assembly station and monitored by a controller of the assembly station, and (iv) while tugging on the target wire, observing for a third light output of the current visual instruction indicating that the pulling force has satisfied a threshold indicative of a proper wire-terminal portion seating and, in response to observing the third light output, stopping tugging on the target wire to complete the current push-click-tug procedure associated with the current visual instruction, and upon properly completing the set of push-click-tug procedures, freeing the connector from the latching system to obtain the wired connector.

DETAILED DESCRIPTION

As discussed above, a large number of wired connectors assembled using conventional assembly systems and methods do not pass testing, leading to decreased first time quality (FTQ) metrics and increased costs to fix improperly assembled wired connectors. This improper assembly typically involves one or more wires of the wired connector not being properly seated in a corresponding terminal portion of the connector. Thus, while these conventional assembly systems and methods work well for their intended purpose, an opportunity exists for improvement in the relevant art. Accordingly, improved wired connector assembly systems and methods are presented herein. These systems and methods assist an assembler in the proper assembly of a wired connector comprising a set of wires seated in a set of respective terminal portions of a connector. These improved wired connector assembly systems and methods provide for the instruction and verification of proper wire-terminal portion seating, thereby increasing FTQ metrics and decreasing costs to fix improperly assembled wired connectors. In addition, less extensive training/knowledge by human assemblers is required, which could further decrease costs and provide for more task flexibility at an assembly plant or facility.

Referring now toFIG. 1, a view of an example wired connector100assembled using the assembly systems or methods according to some implementations of the present disclosure is illustrated. As shown, the wired connector100comprises a connector104(also known as a connector header, wire housing, or terminal) that defines a plurality of terminal portions108in which a plurality of respective wires112are seated. Each terminal portion108, for example, could be a cavity defined in the connector104and having a metallic or other conductive seating element disposed therein. The plurality of wires112could also be electrically connected at their opposing ends to another connector/device/system (not shown). While many wired connectors include a plurality of wires112seated in a plurality of respective terminal portions108, it will be appreciated that in some implementations the wired connector100could comprise a single wire112seated in a single respective terminal portion108. Thus, these components will now be referred to herein as a set of terminal portions108(i.e., one or more terminal portions) and a set of wires112(i.e., one or more wires). As discussed above, one well-known procedure for performing a proper wire-terminal portion seating is the “push-click-tug” procedure where a wire is “pushed” into the respective terminal portion until a “click” indication is observed (a sound, a vibration, etc.) and the seating is then tested and verified by a “tug” on the wire, which will be discussed in greater detail below.

Referring now toFIG. 2, a functional block diagram of an example wired connector assembly system200according to some implementations of the present disclosure is illustrated. The assembly system200comprises an assembly sub-system or station204that is utilized by an assembler208in the assembly of a wired connector, such as wired connector100. It will be appreciated that the term “station” as used herein refers to a device/unit or system of devices/units that are separate from other components (i.e., a sub-system) of the larger assembly system200illustrated inFIG. 2and described below. While the components of wired connector100will be referred to herein for illustration/reference, it will also be appreciated that the assembly system200could be utilized to assembly any suitable wired connector. It will further be appreciated that the term “assembler” as used herein could refer to a human operator/user as well as an automated assembler system, such as a robotic assembler or robotic assembly system. The assembler208utilizes the assembly station204and a set of instructions output therefrom to properly seat the set of wires112in the respective set of terminal portions108of the connector104. Depending on the type of the assembler208, this set of instructions could be audible, visual, and/or haptic instructions, or could be computer-executable instructions (e.g., a software routine). The connector104is retrieved by the assembler208from a set of connector containers216of a supply system212. Each connector container216, for example, could store a different type of connectors. The connector104is scanned or otherwise identified by a scanning device220of the supply system212. While shown as a separate device, it will be appreciated that the scanning device220could be integrated into the assembly station204. By scanning and identifying the type of the connector104, the assembly station204can identify and obtain a proper set of instructions for assembling the wired connector100.

Upon identifying and retrieving the connector104, the assembler208then fixes the connector104within the assembly station204. This fixing of the connector104within the assembly station204, for example, could trigger or initiate the output of a set of instructions for the assembler208as to how to properly seat the set of wires112within the respective set of terminal portions108. According to this set of instructions, the assembler208then retrieves the set of wires112from identified container(s) of a set of wire containers224of the supply system212. Each wire container224, for example, could store one or more different types of wires. In one implementation, a guide system228outputs the set of instructions. Some portions of this guide system228could be integrated into the assembly station204(described in greater detail below) and other portions of the guide system228, such as a visual indicator system232, could be separate or distinct from the assembly station204, such as part of the supply system212as illustrated (e.g., in or proximate to the sets of containers216,224). The visual indicator system232is configured to output a set of visual instructions (e.g., light outputs) that instruct the assembler208as to which container216,224to retrieve the connector104and/or the set of wires112from. It will be appreciated that the visual indicator system232could only provide visual indicators relative to the wire containers224as the connector104could be selected by the assembler208and then scanned by the scanning device220to initiate the assembly process. In one example implementation, the visual indicator system232comprises a set of lights, such as one light or set of lights per container216,224. It will also be appreciated that different types of light outputs could be generated, such as a flashing light output until a particular action is completed. The outputting of the set of instructions could be controlled by a controller236(e.g., a programmable logic controller, or PLC) of the assembly station204, which could also verify the proper seating of the set of wires112in the respective terminal portions108, such as based on measured pull force and one or more pull force thresholds, which could be calibrated at the controller236using a handheld tensiometer240or other suitable device/system.

Referring now toFIGS. 3A-3B and 4A-4Band with continued reference toFIG. 2, an example configuration300of the assembly station204of the assembly system200is illustrated. This will be hereinafter referred to as assembly station300.FIGS. 3A-3Billustrate the fixing of the connector104within the assembly station300andFIGS. 4A-4Billustrate exploded views of the assembly station300. The assembly station300comprises a base member304that has a latching system308attached thereto. In one exemplary implementation as shown, the latching system308is a pneumatic latching system that comprises a receptacle312defined in a central member316. The receptacle312is defined to receive the connector104as well as other types of connectors. In this pneumatic latching configuration, the latching system308further comprises latching members324a,324bthat move inwardly and outwardly (between closed and open positions) from respective end members320a,320band along an axis of movement328. In the closed position, the latching members324a,324bfixably contact the connector104to secure it therein, whereas in the open position the latching members324a,324bdo not contact the connector104thereby freeing or releasing it from the receptacle312. The latching system308could be electronically controlled by the controller236and, in some implementations, could also be mechanically controlled via a manual release switch332and a manual release control lever356. On an opposing side of the base member304, a display device336is attached. The display device336could be, for example only, a human-machine interface (HMI) display that is configured to output visual instructions to the assembler208, through a hole or opening340defined in the base member304and aligned with the display device336, as to which terminal portions108to seat which wires112.

Also attached to the base member304area pair of force or load sensors344a,344b. In one exemplary implementation as shown, the pair of load sensors344a,344b(also referred to herein collectively as “a sensor system” or “sensor system344”) are arranged proximate to diagonally opposing corners of the opening340to thereby provide for a more even or uniform pull force sensing on the base member304via the fixed connector104. While a single pair of force or load sensors344a,344bare shown, it will be appreciated that other quantities of load sensors could be implemented. For example only, there could be two separate pairs of load sensors, with the load sensors in each pair of load sensors being arranged in series. In one exemplary implementation, the load sensors344a,344bcomprise load cells348a,348band load cell compressive bars352a,352b, respectively. In some implementations, the load cells348a,348band load cell compressive bars352a,352bare covered or held together by load sensor cover members360a,360bin load sensor receptacles364a,364b, respectively. While a load cell/bar type configuration is specifically described and illustrated herein, it will be appreciated that any suitable type of pull force sensor could be utilized (mechanical strain gauge, piezoelectric strain gauge, etc.). As previously discussed herein, the pull force threshold(s) utilized by the assembly station300(i.e., by the controller236) could be calibrated for each specific application, such as by using the handheld tensiometer240. In one exemplary implementation, different pull force thresholds are utilized for proper wire-terminal portion seating verification and for emergency release of the connector104to prevent potential damage. It will also be appreciated that the specific configuration of the assembly station300shown inFIGS. 3A-3B and 4A-4Bis merely one example configuration and there could be many other suitable configurations for the assembly station204.

Referring now toFIG. 5and with continued reference toFIGS. 2, 3A-3B, and4A-4B, a flow diagram of an example wired connector assembly method500of using the assembly station300ofFIGS. 3A-3B and 4A-4Baccording to some implementations of the present disclosure is illustrated. At504, the controller236outputs a set of connector instructions. This could include, for example, commanding the guide system228(e.g., the visual indicator system232) to identify a particular connector container216having the target connector104. At508, the controller236determines whether the target connector104has been obtained, e.g., using the scanning device220. When true, the method500proceeds to512. Otherwise, the method500returns to504. At512, the controller236determines whether the connector104is fixed by and within the receptacle312of the latching system308. When true, the method500proceeds to516. Otherwise, the method500returns to504. At516, the controller236commands the guide system228to sequentially output a set of instructions instructing the assembler208how to properly seat the set of wires112in the set of terminal portions108of the connector104. In one exemplary implementation, each instruction comprises one or more visual instructions (i.e., a respective set of visual outputs), such as a visual (e.g., light) output by the visual indicator system232as to which wire container224that the assembler208is to retrieve the target wires112from and another visual (e.g., light) output by the display device336as to which target terminal portion108that the assembler208is to seat each target wire112.

At520, the controller236determines whether the sensed pulling force (e.g., as measured by load sensors344a,344b) satisfies a second threshold (TH2). This second threshold TH2is indicative of a pulling force that could potentially damage the connector104. When this second threshold TH2is satisfied at520, the method500proceeds to532where the controller236commands the latching system308to the open position to release the connector104. Otherwise, the method500continues to524. At524, the controller236determines whether the sensed pulling force (e.g., as measured by load sensors344a,344b) satisfies a lesser first threshold (TH1). This first threshold TH1is indicative of a proper wire-terminal portion seating. When this first threshold TH1is satisfied, the method500proceeds to528. Otherwise, the method returns to516. At528, the controller236determines whether the set of instructions have completed. The completion of the set of instructions is also indicative of the verification of the proper wire-terminal portion seating for each of the set of wires112in the respective set of terminal portions108. When false, the method500returns to516. When true, however, the method500proceeds to532where the controller236or the assembler208(e.g., via manual release switch332) commands or controls the latching system308to the open position to release the fully assembled wired connector100. The method500then ends or returns to504for another assembly cycle.

Referring now toFIG. 6and with continued reference toFIG. 2, a flow diagram of another example wired connector assembly method600using the assembly system200ofFIG. 2including a set of push-click-tug procedures according to some implementations of the present disclosure is illustrated. At604, the assembler208obtains the target connector104(e.g., from a target connector container216as identified by the guide system228). At608, the assembler208obtains the target set of wires112(e.g., from target wire container(s)224as identified by the guide system228). It will be appreciated that the set of wires112could be sequentially obtained during the output of the set of instructions and not initially obtained all at once. At612, the assembler208fixes the connector104in the assembly station204of assembly system200. At616, the assembler208observes for a first light output by the guide system228that is indicative of a target wire112for a current push-click-tug procedure and could be initiated in response to the connector104being properly fixed in the assembly station204. When the first light output is observed by the assembler208, the method600proceeds to620. Otherwise, the method returns to612.

At620, the assembler208obtains the target wire112as instructed by the first light output. At624, the assembler208observes for a second light output that is indicative of a target terminal portion108in which the assembler208is to seat the target wire112. When the second light output is observed by the assembler208, the method600proceeds to628. Otherwise, the method600returns to620. At628, the assembler208inserts and pushes the target wire112into the target terminal portion108of the connector104. At632, the assembler632observes for a click indication. As previously described herein, this click indication could be an audible response (e.g., a click sound) and/or a haptic response (e.g., a vibration). When the click indication is observed by the assembler208, the method600proceeds to636. Otherwise, the method600returns to628. At636, the assembler208tugs or pulls on the target wire112, which causes a pulling force on the connector104that is measured/monitored by the controller236of the assembly station204. At640, the assembler208observes for a third light output that is indicative of the pulling force satisfying a threshold indicative of a proper wire-terminal portion seating. When the third light output is observed by the assembler208, the method600proceeds to644where the assembler208ceases tugging or pulling on the target wire112as it is properly seated. Otherwise, the method600returns to636. At648, the assembler208or the controller236determines whether the set of instructions corresponding to the set of push-click-tug procedures have completed. When true, the method600proceeds to652. Otherwise, the method600returns to616where the instructions and the push-click-tug procedures continued. At652, the assembler208or the controller236releases the connector104from the assembly station204to thereby obtain the fully assembled wired connector100. The method600then ends or returns to604for another assembly cycle.

As used herein, the term module may refer to, be part of, or include: an Application Specific Integrated Circuit (ASIC); an electronic circuit; a combinational logic circuit; a field programmable gate array (FPGA); a processor or a distributed network of processors (shared, dedicated, or grouped) and storage in networked clusters or datacenters that executes code or a process; other suitable components that provide the described functionality; or a combination of some or all of the above, such as in a system-on-chip. The term module may also include memory (shared, dedicated, or grouped) that stores code executed by the one or more processors.