Design and research on automatic insertion and bending wire device for power socket and soft wire connections

To solve the problem of low efficiency involved in manually inserting power sockets into soft wires, a new system called an automatic insertion wire device of mechanical arm as a part of intelligent agents has been designed. It has a manipulator end lead channel actuator, a two-degree-of-freedom manipulator, a scissor bending mechanism and a control system. A coordinate system has been established for kinematics analyses and inverse kinematics solution. The joint angles of the manipulator when reaching the terminal hole of the power socket are 47.7° and 91.3° for joint angles 1 and 2, respectively. The motions of the scissor bending mechanism are analyzed using a coordinate system, and the rotation angle of support rod 1 is found to be 32.3° after the completion of soft wire bending. A model of the actuator and scissor bending mechanism is created using SolidWorks, and motion simulations are carried out to verify the insertion of soft wire. A prototype is built and tested, which demonstrates that the angle variation range of the soft wire head part due to push block movement is between 58° and 63°, while the angle variation range of the shear fork bending mechanism to other parts of the soft wire is between 168° and 173°. All parameters meet the anticipated goal, effectively resolving the problem of low efficiency.