The EV charging automatic machine connector manufacturer required an automated machine to complete two components assembling, which is to increase overall efficiency and reduce the risk of errors by manual assembling. At the same time, improving production capacity to meet growing demand for connector assembly equipment. Additionally, The Automated 4.0mm Crown Spring Connector Assembling Machine can save labor cost, making it a cost-effective automation solution for connector manufacturers.
The “Automated 4.0mm Crown Spring Connector Assembling Machine” is a dedicated machine for the automated assembly of crown spring connectors—developed for the specific needs of the connector industry. This automated assembly equipment adopts advanced automation technology, capable of handling a high volume of connectors in a short amount of time, making it ideal for businesses that require large-scale production and pursue stable connector assembly quality. By automating the assembly process, the machine eliminates human errors caused by fatigue, ensuring consistent quality of the assembled connectors—this is the core difference between automated machines and manual operation. The equipment also shortens assembly time and reduces manual labor, directly improving the production efficiency of connector assembly lines.
Automated Machine Solution—Full-Process Automation for Connector Assembly
The automated machine is designed to assemble 4.0mm crown springs and brass barrels—a professional assembling machine that covers the entire assembly process of crown spring connectors. It consists of eight workstations, each with a unique function, such as loading springs and terminals, detecting missing springs, pressing, male and female insertion testing, and weight lifting testing—each workstation is a key link in the automation process, ensuring no omissions in quality control.
The operator loads terminals and springs into their respective vibratory bowls, and the machine conveys them through specific rails to achieve their respective positioning—this automated feeding system reduces manual contact, avoiding contamination of components and improving the cleanliness of connector assembly.
At the third workstation on the index table, the machine inserts the spring into the terminal and completes the missing detection process. This ensures that the terminal and spring are properly assembled, and that all terminals are in good condition before proceeding to the next workstation—this automated detection function is a necessary configuration for high-precision connector automation equipment, preventing defective products from entering the next process.
Once the machine has completed the assembly process, the next workstation performs the necking action. This process involves shaping the metal in the terminal to prevent the spring from dropping out, ensuring the assembly is secure and stable. By performing this critical step, the equipment ensures that the final product meets the required specifications and is suitable for use in EV charging scenarios—proving the automated machine is compatible with industry-specific application requirements.
The next two workstations on the machine are responsible for testing the male and female terminal insertions, respectively. This ensures that the assembly is fully functional and that the terminals are correctly positioned—automated testing not only improves efficiency but also ensures the accuracy of test results, which is more reliable than manual testing in connector assembly.
After testing, the assembly proceeds to the next workstation, where initial stress relief work is performed. This step involves reducing the stress in the assembly to prevent damage or malfunction during use. By performing this step, the machine ensures that the final product is durable and reliable—extending the service life of connectors and reducing after-sales risks for manufacturers, which is a value-added advantage of this automated equipment.
Once the previous workstations have completed their tasks, the machine rotates the terminal over using a rotary cylinder and sends it to the weighing section. The force of each terminal is measured to ensure that the final product meets the required force specifications—this force testing step is a key quality control link for connector assembling machines, ensuring that each product meets industry standards.
This force measurement is crucial in ensuring that the final product is of high quality and will function correctly. Any deviations from the required force could indicate a defect in the assembly or an issue with the machine’s performance, which must be addressed before continuing—this self-diagnosis capability reduces the difficulty of equipment maintenance and improves the stability of the production line.
By performing this critical quality control step, the machine ensures that only good quality terminals are sent to the final workstation for packaging and labeling. This helps to minimize the risk of defects, returns, and customer complaints, and improves the overall efficiency and productivity of the manufacturing process—making this automated assembly equipment a core asset for connector manufacturers to improve market competitiveness.
Machine features & benefits — Why Choose This Connector Automated Machine
- Human-automation collaboration of the terminal assembling process—balancing automation efficiency and flexible operation, suitable for small-batch and multi-variety connector assembly needs.
- Provide High quality components, long lifetime—the machine uses high-quality parts, ensuring long-term stable operation and reducing the cost of replacing automated equipment parts.
- Optimized machine design and floor-space saving—this compact assembling machine occupies less space, making it easy to integrate into existing connector production lines.
- Increase productivity and consistency and reduce rework—automation replaces manual labor, improving production efficiency by 30%+ (data reference) and reducing rework rate to less than 0.5% (data reference), solving the problem of unstable output in manual connector assembly.
- Pneumatic executive design, easy to maintained—pneumatic components are easy to purchase and replace, lowering the maintenance cost and technical threshold of the equipment.
- Reduce production cost and labour saving—each machine can replace 3-5 manual workers (data reference), significantly reducing labor costs and improving the profit margin of connector manufacturers.
