CHAD Wire Harness Connector Assembly System

SYSTEM OVERVIEW

The CHAD WHC Assembly System significantly improves production yields and cycle times for the arduous wire harness connector assembly process . This low cost, highly ergonomic, semi-automatic system streamlines the wire and seal plug insertion process by providing operator assistance in the identification, placement and confirmation of each wire and seal plug as it is assembled into a connector. The CHAD WHC Assembly System Software Operator Interface is extremely user-friendly, intelligently guiding the operator step-by-step, through the entire connector assembly process. The CHAD WHC system is industrially design to meet the rigors of the production floor while providing key ergonomic features to minimize operator fatigue. The CHAD WHC Assembly System provides a revolutionary new solution for automated wire harness connector assembly reducing mis-wiring defects, rework costs and maximizing operator productivity and comfort.

SYSTEM OPERATION

The CHAD WHC Assembly system includes the following key sub-systems:

•Connector and Wire Identification with Bar Code Reader •Connector Positioning Device with Universal Connector Fixture•Laser Light Pointer and Detector•PC-based Graphical Operator Interface Software

•Connector and Wire Identification with Bar Code ReaderUsing a hand held bar code scanner, the CHAD WHC Assembly system first identifies the selected connector and then loads the appropriate assembly data. Next, it identifies each selected wire or seal plug and directs the X-Y connector positioning stage and laser to the appropriate location for insertion of each wire or seal plug until the assembly is complete.

•Connector Positioning Device with Universal Connector FixtureThe system uses a universal connector fixture integrated onto a motorized X-Y stage to enable mounting and positioning of a variety of circular (diameters from .75" up to 3") and square Mil-Spec connector styles.

•Laser Light Pointer and DetectorUsing top down laser light guidance, the system intelligently guides the operator to the proper insertion location in a given connector and verifies that the location is unblocked and available for wire or seal plug insertion. This laser guidance is extremely critical for successfully dealing with wire and seal plug insertion locations that can become obstructed by previously inserted wires. Once a wire or a seal plug has been inserted, the X-Y stage positions the connector under the laser pointer and a bottom side sensor receives the light from the laser pointer to indicate an empty contact hole prior to insertion and an occupied hole after insertion.

•PC-based Graphical Operator Interface SoftwareThe CHAD WHC Assembly System Software Operator Interface makes the system user-friendly enough for even the least experienced operator to use. Using preprogrammed connector assembly recipes, the system automatically positions the fixtured connector under the laser light and visually guides the operator through the process of inserting wire conductors or seal plugs, and then confirms successful insertion.

Corporate Headquarters 1565 S. Sinclair Street, Anaheim, CA 92806 PHONE 714.938.0080FAX 714.938.0630WEB www.chadindustries.net

CHAD WHC Assembly System

Corporate Headquarters 1565 S. Sinclair Street, Anaheim, CA 92806

PHONE 714.938.0080FAX 714.938.0630WEB www.chadindustries.net

CHAD WHC Assembly System Customer Testimonial

“With the introduction of the CHAD Semi-Automated Wire Insertion System, we have now made a “quantum leap” over our competition.”

Key Benefits: •Yield improvement of 25% or more•Zero defects on mis-wired connectors•>25% labor savings•>25% cycle time improvement•Significant annual rework savings•Universal connector fixture handles virtually all connector styles

Key Features:•Mil-Spec circular connector diameters from .75" to 3" - standard•Laser Light Insertion Guide (Class IIa laser)•Wire and Seal Plug Presence/Absence Detection Sensing•Servo Motor Based X-Y Connector Positioning Mechanism•Ergonomic Adjustable Arm Rest•Adjustable Height Steel Frame/Worktable •Bar Code Scanner•WindowsNT based Controller •User-friendly Operator Interface •Flat Screen Monitor•Password Control for Operators, Technicians, and Administrators•Storage Drawers•Task Light•Optional Universal Connector Fixture for Square Mil- Spec Connector Styles•Optional Laser Printer•Optional UPS for PC

Reliability, Service and Support:•Proven industrial design for reliability under the most stringent volume production requirements•All platform components are designed, built and serviced in the USA•Support through CHAD's existing factory automation customer service network

For more information, please contact:

Chad Industries, Inc.1565 S. Sinclair StreetAnaheim, CA 92806PHONE 714.938.0080FAX 714.938.0630

WEB www.chadindustries.net

CHAD Wire Harness Connector Assembly System

CHAD WHC Assembly System