A method 500 of operating an automated machine 100 is provided for inserting wires into grommet cavity locations 110 of an electrical connector 112 to compensate for manufacturing tolerances associated with the electrical connector. The method comprises inserting wires into grommet cavity locations of the electrical connector based upon a plug map 300 having offset values to compensate for manufacturing tolerances associated with the electrical connector. The method may further comprise selecting from a plurality of pre-generated plug maps having offset values the closest matching pre-generated plug map for the electrical connector based upon offset values associated with each of the plurality of pre-generated plugs maps. The selected pre-generated plug map having offset values corresponds to the plug map used to insert wires into grommet cavity locations of the electrical connector.

A method for calibrating a second bonding machine based on a calibrated first bonding machine is disclosed. The first bonding machine includes a first ultrasonic transducer. The second bonding machine includes a second ultrasonic transducer and a power supply. The method includes providing a first electrical calibration supply that causes the first ultrasonic transducer to oscillate at a first calibration amplitude when it is damped by a mechanical damping, providing a second electrical calibration supply that causes the second ultrasonic transducer to oscillate at the same calibration amplitude when it is damped by the same mechanical damping. The second bonding machine is adapted to modify a second control signal based on a first electrical parameter of the first electrical calibration supply and on a second electrical parameter of the second electrical calibration supply in order to generate a modified second control signal, provide the modified second control signal to the power supply in order to cause the second power supply to generate a second electrical supply, and provide the second electrical supply to the second ultrasonic transducer.

A control unit includes a position command generation unit generating a position command, a position control unit outputting a first speed command such that detected position tracks the position command, a pressure command generation unit generating a pressure command, a pressure control unit outputting a second speed command such that detected pressure or force tracks the pressure command, a speed command selection unit selecting creep speed, the first speed command, or the second speed command and outputs it as a speed command for the motor to operate; and a speed control unit outputting a current command for supplying current to the motor such that the motor speed tracks the speed command output by the speed command selection unit. After selecting the first speed command, the speed command selection unit selects the second speed command or the creep speed at timing when the first speed command falls below the creep speed.

A control unit includes a position command generation unit generating a position command, a position control unit outputting a first speed command such that detected position tracks the position command, a pressure command generation unit generating a pressure command, a pressure control unit outputting a second speed command such that detected pressure or force tracks the pressure command, a speed command selection unit selecting creep speed, the first speed command, or the second speed command and outputs it as a speed command for the motor to operate; and a speed control unit outputting a current command for supplying current to the motor such that the motor speed tracks the speed command output by the speed command selection unit. After selecting the first speed command, the speed command selection unit selects the second speed command or the creep speed at timing when the first speed command falls below the creep speed.