Dual-End Multi-wire Crimping and Housing Insertion Machine

This machine uses a multi-line simultaneous processing method: multiple individual wires are fed and processed at the same time so that cutting, stripping, crimping and housing insertion can be completed concurrently for 2–12 wires (or 2–12 rows). Housings are auto-fed via a vibrating plate and multiple wires are handled in parallel, which dramatically increases production throughput and reduces per-unit labor time.

The system’s modular design allows each functional block—strip, crimp, insertion—to be enabled or disabled through software. With insertion disabled, the equipment functions as a conventional double-sided automatic crimping machine. Changing to different terminal types requires only replacement of the crimp applicators, vibrating plate feeder and insertion jigs, enabling fast changeovers and minimizing idle time.

High-precision servo drives power the cutting, stripping and linear translation mechanisms; the blade uses a positive-and-negative screw arrangement and the translation mechanism keeps wires straight during processing for improved positioning accuracy and process stability. The crimping assembly is integrally cast from ductile iron to ensure rigidity and stable crimp height. Optional inline quality systems include a crimping force monitor and CCD visual inspection to detect anomalies and verify crimp appearance and dimensions in real time.

Operation is intuitive via a color touch-screen HMI with program memory for rapid recall of processing parameters. An optional industrial computer control system with network interface supports MES connection over LAN to allow remote parameter access and production task management. Additional optional accessories include a long-wire conveyor, safety shield, crimping force monitor, visual inspection system and computer industrial control system.

Important operational limits: because the machine processes multiple wires in parallel, all wires in a single run must be the same length; the system is designed for single-row (single-line) housing pin configurations only and does not support complex double row housing or crossing-insertion housing arrangements. These constraints make the machine ideal for high-volume runs of uniform-length, single-row connector assemblies but unsuitable for mixed-length or multi-row/cross-insertion applications.