Automated Dual-End Crimping and Single-End Housing Insertion Machine

This machine is a fully integrated wire processing system that performs dual-head terminal crimping and single-head connector housing insertion in one continuous workflow. It combines wire cutting, stripping, terminal crimping at both ends and housing insertion at a single end, enabling efficient assembly of connectors and harnesses.

Standard configuration supports six wire colors via a six-station wire prefeeder (expandable by customization). Each color’s length can be set independently, and wires from the same color can be reused in sequence so the system can feed and crimp multiple wires before inserting them into a multi-hole housing via vibration-plate housing feeding.

The platform is modular and software-configurable: functional modules (cut/strip, crimping, housing insertion, tinning, etc.) can be enabled or disabled as needed. With housing insertion turned off, the unit operates as a conventional double-head automatic terminal crimping machine. Changing product types requires only swapping crimping dies, vibration feeder plates and inserting jigs for fast, low-waste changeovers.

High-precision servo motors drive both cutting/stripping and linear translation mechanisms. A positive/negative screw cutting blade and linear translation keep wires straight during processing for superior positioning accuracy compared with rotary mechanisms, making the system suitable for demanding wire specifications.

The terminal crimping assembly is integrally machined from ductile iron for rigidity and stable crimp height. Optional quality features include a terminal pressure monitor for real-time crimp-force curve tracking and automatic alarm/stop on anomalies, and an optional CCD visual inspection system for post-crimp appearance and dimensional checks. Operation is via a color touchscreen with program memory; an industrial PC/MES-capable control option enables remote parameter access, production task management and rapid recall of saved setups.