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 busbar is placed on an anvil, and a core wire of a cable is placed on the busbar. While the core wire is pressed onto the busbar using a horn chip, ultrasonic vibration is given to the core wire to join the core wire to the busbar. The horn chip has two flat portions and a recessed portion located between the flat portions. When the core wire is pressed onto the busbar using the horn chip, each of the flat portions and the busbar sandwich a part of the core wire therebetween while the recessed portion and the busbar put a remaining part of the core wire therebetween. Each of the sandwiched parts of the core wire does not reach an outer end of the corresponding flat portion to leave a space between the corresponding flat portion and the busbar.

A terminal-equipped electric wire manufacturing method includes: an electric wire installation step of inserting a core-wire exposed part between inner wall surfaces of piece parts of a core-wire connection body, the core-wire exposed part having a core-wire diameter smaller than an interval between the inner wall surfaces of the piece parts; a melting step of melting the core-wire exposed part and the core-wire connection body by emitting a laser beam to the core-wire exposed part and the core-wire connection body from a free end side of each piece part; and a fixation step of fixing the core-wire exposed part and the core-wire connection body thus melted, with the emission of the laser beam stopped.

A method of manufacturing a terminal-equipped electrical wire includes: inserting a core-wire exposed part of a core wire of an electrical wire at a terminal between inner wall surfaces of a pair of piece parts of a terminal fitting including a core-wire connection body formed of a bottom part and the piece parts protruding from both ends of the bottom part, and placing the core-wire exposed part on an inner wall surface of the bottom part; melting the core-wire exposed part and the core-wire connection body by emitting a laser beam to the core-wire exposed part and the core-wire connection body from a free end side of each piece part; and fixing the core-wire exposed part and the core-wire connection body melted by the laser beam, with the emission of the laser beam stopped.

A soldering aid for securing a stranded core of a cable on an electrical contact surface of a printed circuit board includes an outer part having a receptacle and a bearing surface, and an inner part that is displaceably received inside the receptacle of the outer part. The inner part has an access opening through which the contact surface is accessible and can be fastened to the outer part in an assembly position. In an inserted position of the inner part in the outer part, an insertion opening in the inner part is aligned with an insertion opening in the outer part for inserting the stranded core of the cable.

A connector includes a terminal, an electric wire, and a housing having a tubular portion that accommodates the terminal and the electric wire therein. An electric wire connection portion and a terminal connection portion are provided on both end sides of the terminal. The electric wire connection portion is connected to the electric wire. A joining portion between an end surface of the electric wire connection portion and an end surface of the electric wire includes a protruding piece protruding in a radial direction of the electric wire connection portion. A first retaining piece and a second retaining piece configured to be locked to the protruding piece are provided on an inner peripheral surface of the tubular portion. The second retaining piece is disposed at a position shifted from the first retaining piece in both a circumferential direction and an axial direction of the tubular portion.

A welding system comprises a welding module and a moving module adapted to move the welding module to a predetermined welding position. The welding module includes a guiding device and a welding tool. The guiding device has a plurality of tubular guiding heads arranged in a row, ends of the plurality of tubular guiding heads are disposed close to joints of a plurality of cables so as to guide a plurality of welding wires to the joints of the plurality of cables. The welding tool has a plurality of tooth-shaped welding heads arranged in a row, ends of the plurality of tooth-shaped welding heads are disposed close to the joints of the plurality of cables and configured to simultaneously heat the plurality of welding wires guided to the joints of the plurality of cables, so as to simultaneously weld the joints of the plurality of cables onto a circuit board.

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 method for welding at least three cables, each with two conductors protruding from the sheath ends of the cables includes stripping ends of the first conductors and stacking from opposite directions atop one another forming a first stack. The stripped ends of the second conductors are stacked atop one another from opposite directions at a working distance from the first stack forming a second stack. The first stack is arranged in a welding area of a welding device and welded to a first welding point, while the second stack is arranged in a waiting area spaced by the working distance from the welding area. The first welding point is moved by the working distance from the welding area to a storage area, while the second stack is moved by the working distance from the waiting area into the welding area and is welded to a second welding point.

A cable connection structure is provided with an electronic component including electrodes on an electrode-forming surface, a cable including electric wires connected to the electrodes respectively, and a buried member which is composed of a cured resin and embedded with the electric wires. At least three electric wires are separating wires including separating regions being separated from each other in the normal direction as being distant from the electrode-forming surface. At least three electrodes are arranged side by side on a virtual circle. At least three separating wires are connected to the at least three electrodes. The separating regions of the at least three separating wires are provided to be located eccentric radially outwardly in the virtual circle as being distant from the electrode surface in the normal direction of the electrode-forming surface. An angle between the separating region and the normal direction of the electrode-forming surface is 10 degrees or more and 45 degrees or less.