A connection method of a terminal includes an inserting-arranging process for inserting and arranging conductors of a plurality of wires into a connection section. The wires have the conductor sections exposed from the sheaths thereof at the end portions. The connection section has cylindrical shape with a bottom portion and an opening section. The method further includes a heating-melting process for heating the connection section in a state that the opening section of the connection section faced upwards in the vertical direction to melt the conductors within the connection section, and a molten-metal raising process for conducting an insertion of the conductors into the connection section and/or a pressurization of the connection section from outside to raise the molten metal within the connection section to a level upper.

A robotic wire termination system for efficiently and accurately connecting a plurality of wires to an electrical connector having a plurality of connector pins with corresponding wire receptacles. The system generally includes a housing, a removable alignment plate, a robotic positioner, a heating device, a touch responsive display, and a control unit. The alignment plate removably holds a selected electrical connector in a specific position and orientation with the connector pins exposed in the housing and the wire receptacles exposed outside. The display provides a visual representation of the connector pins and selections of the connector pins. The control unit receives inputs indicating the pin selections and controls the robotic positioner to sequentially move the heating device along three orthogonal longitudinal axes to a series of heating positions relative to the selected connector pins to provide heat for melting solder to connect wires to the wire receptacles.

A robotic wire termination system for efficiently and accurately connecting a plurality of wires to an electrical connector having a plurality of connector pins with corresponding wire receptacles. The system generally includes a housing, a removable alignment plate, a robotic positioner, a heating device, a touch responsive display, and a control unit. The alignment plate removably holds a selected electrical connector in a specific position and orientation with the connector pins exposed in the housing and the wire receptacles exposed outside. The display provides a visual representation of the connector pins and selections of the connector pins. The control unit receives inputs indicating the pin selections and controls the robotic positioner to sequentially move the heating device along three orthogonal longitudinal axes to a series of heating positions relative to the selected connector pins to provide heat for melting solder to connect wires to the wire receptacles.

A wire connection structure for electrically connecting ends of a plurality of core wires, each of which is exposed by stripping a coating at an end region of each of a plurality of wires arranged in parallel, to terminals corresponding to the plurality of wires, includes a fixing member that contacts outer circumference surfaces of the plurality of wires in a vicinity of the end region and fixes relative positions between the plurality of wires, with the plurality of wires being aligned parallel to each other in the vicinity of the end region.

A wire connection structure for electrically connecting ends of a plurality of core wires, each of which is exposed by stripping a coating at an end region of each of a plurality of wires arranged in parallel, to terminals corresponding to the plurality of wires, includes a fixing member composed of a resin molded body that contacts outer circumference surfaces of the plurality of wires in a vicinity of the end region and fixes relative positions between the plurality of wires, with the plurality of wires being aligned parallel to each other in the vicinity of the end region, wherein a tearing portion that can be torn along a longitudinal direction of the wires for being extremely thin or is torn along the longitudinal direction is formed for each wire at a part of a region contacting the outer circumference surface.

A robotic wire termination system for efficiently connecting a plurality of wires to an electrical connector. The robotic wire termination system generally includes a frame, a connector support attached to the frame, a robot manipulator having at least one arm, a heating device attached to the at least one arm and a control unit in communication with the robot manipulator to control the operation of the robot manipulator. The arm of the robot manipulator is adapted to move the heating device so that the heating device can apply heat to a selected connector pin of the electrical connector.

A method for connecting a conductor wire to an electrode that is formed on a substrate includes placing the conductor wire on the electrode while tension is applied to the conductor wire, and soldering the conductor wire to the electrode while the conductor wire is pressed toward the substrate by a heating element.

A terminal fixing method, for fixing one or more terminals to a plurality of lands provided on a substrate by laser welding, includes: constructing the plurality of lands by one or more terminal installation lands on which the terminals are installed and one or more dummy lands each larger than each of the terminal installation lands; irradiating each of divided laser beams emitted from a laser oscillator toward a corresponding land of two or more lands in the plurality of lands by the laser welding; and constructing the two or more lands by two or more terminal installation lands in the terminal installation lands, or one or more terminal installation lands in the terminal installation lands and the one or more dummy lands.

A method of manufacturing a connector, in which a plurality of central conductors each exposed at an end portion of an insulated wire are soldered, in a one-to-one correspondence, to a plurality of connectable portions arranged side by side on a substrate, includes placing the plurality of central conductors in a one-to-one correspondence with the plurality of connectable portions at each of which solder is disposed and pressing the plurality of central conductors placed in the placing against the plurality of connectable portions. In the pressing, the plurality of central conductors are heated and pressed by using a pressing jig. The pressing jig includes a cushion portion and a heat-conductive portion sequentially in a direction in which the pressing jig presses the plurality of central conductors.

A robotic wire termination system for efficiently connecting a plurality of wires to an electrical connector. The robotic wire termination system generally includes a frame, a connector support attached to the frame, a robot manipulator having at least one arm, a heating device attached to the at least one arm and a control unit in communication with the robot manipulator to control the operation of the robot manipulator. The arm of the robot manipulator is adapted to move the heating device so that the heating device can apply heat to a selected connector pin of the electrical connector.