Optimizing Robotic Tools for Wire Cutting and Crimping

This research describes the development of compact and efficient tools which can be used by a 4-DOF robot during an automated process aimed at the building of heating coils. Resistive wires must be cut and crimped into small connectors at a fast pace, with extreme repeatability and reliability. We designed two special tools for the end effector of a parallel-kinematic robotic device, exploiting a compact and lightweight design. Wire cutting has been obtained by means of two custom blades. A test bed has been build in order to investigate the optimal shape of the blades, hence minimizing the actuating force and wear effects. A new cutting method has been proposed and a final cutting tool has been designed and mounted on the robot. Crimping the resistive wire into miniaturized connectors required the development of small, yet stiff, pneumatic crimping pliers. The cutting tool and the crimping pliers have been mounted on a single multifunctional end-effector. The robot successfully performed the high-speed tests, showing the high performance of the tools.