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ZY-CON-401
The ZY-CON-401 combines connector component feeding, pin stitching, pin bending, header cutting, cleaning, electrical testing, CCD inspection, and product packaging in one coordinated production system.
It is intended for industrial connector programs that require several assembly and inspection operations to run in a defined sequence. The machine delivers at least 2,400 pieces per hour with a utilization rate of at least 90%.
Its modular mechanical structure, intelligent control system, configurable tooling, inspection functions, and data interface allow the equipment to be developed around the connector and its production requirements.
Plastic insulators and contact pins are supplied to the corresponding assembly stations. The feeding method, orientation mechanism, and transfer path are configured according to component geometry and the required cycle.
Contact pins are inserted into the plastic insulator according to the connector design. When the product requires formed terminals, an additional station bends the pins to the specified direction and profile.
Tooling must be matched to the pin material, dimensions, insertion depth, spacing, and allowable force.
The pin header is cut according to the required product configuration. A cleaning process is then applied before inspection to remove production residue that could interfere with subsequent testing or product handling.
Assembled connectors pass through an electrical testing station. Test functions, limits, contact points, fixtures, and pass/fail criteria are configured from the product’s electrical specification.
The vision system checks project-defined visible characteristics after assembly. Inspection items can include component presence, pin position, orientation, spacing, bending profile, or other characteristics that can be evaluated from the available camera view.
Lighting, lens selection, image resolution, inspection position, and acceptance limits are matched to the connector and inspection requirement.
Products that complete the configured assembly and inspection sequence are transferred to the packaging stage. Packaging format and handling method are selected according to the product, production layout, and downstream requirements.
Automatic plastic insulator feeding
Automatic contact pin feeding and stitching
Contact pin bending
Pin header cutting
Product cleaning
Integrated electrical testing
CCD visual inspection
Product packaging
Intelligent machine control
CCD camera and robot integration
Modular and standardized mechanical structure
Servo transmission for configured high-speed operations
Industrial enclosure with controlled access
Host-computer data collection
Production information traceability
MES connectivity
Customized tooling and machine layout
Electrical testing and CCD inspection evaluate different aspects of the finished connector. The electrical station checks the parameters defined in the product specification, while the vision station evaluates visible assembly characteristics.
The inspection plan can be developed around critical product requirements such as:
Presence of required components
Correct component orientation
Pin position and alignment
Pin bending direction and profile
Missing or visibly deformed pins
Assembly position
Product identification
Project-defined electrical results
Each inspection item requires an agreed method, tolerance, pass/fail rule, and response when a nonconforming product is detected.
Reject handling can be configured to separate failed products, stop the affected process, display an alarm, or record the failure information. The selected method depends on the line layout and the required control plan.
The ZY-CON-401 uses a host computer to collect production and inspection data. The recorded information can support equipment monitoring, result review, production tracking, and connector traceability.
Project-defined records may include:
Production order
Product model
Production quantity
Cycle information
Electrical test result
CCD inspection result
Alarm and fault information
Rejected product record
Operator or batch information
Equipment status
The machine can connect with a manufacturing execution system. Communication protocol, data fields, database structure, record retention, permissions, and information exchange rules are defined according to the factory system.
Item | Technical Information |
|---|---|
Model | ZY-CON-401 |
Production efficiency | ≥2,400 pcs/h |
Utilization rate | ≥90% |
Insulator handling | Automatic feeding |
Contact handling | Feeding and stitching |
Forming process | Contact pin bending |
Cutting process | Pin header cutting |
Cleaning process | Product cleaning |
Electrical inspection | Integrated electrical testing |
Visual inspection | CCD inspection |
Final process | Product packaging |
Data handling | Host-computer collection and traceability |
Factory integration | MES connectivity |
Customization | Mechanical, tooling, control, inspection and packaging |
Actual output depends on the connector structure, component-feeding stability, number of assembly operations, inspection cycle, packaging method, changeover requirements, and production conditions.
The equipment can be developed for industrial connector products that use plastic insulators and contact pins. Product images show connector formats including pin headers, multi-position plastic housings, and elongated connector assemblies.
A new connector project should be evaluated using:
Connector assembly drawing
Plastic insulator drawing
Contact pin drawing
Bill of materials
Component samples
Pin count and spacing
Insertion depth and force requirements
Pin bending profile
Cutting position
Product tolerances
Electrical test specification
Visual inspection criteria
Packaging requirements
Connectors with different structures may require dedicated feeders, fixtures, insertion tooling, forming tools, test fixtures, camera arrangements, or change parts.
Feeding systems can be developed for plastic insulators, contact pins, and other required connector components. The method depends on component shape, supply format, surface requirements, and cycle time.
Fixtures and process tooling are designed around the connector drawing, insertion sequence, pin arrangement, forming requirements, and dimensional tolerances.
Electrical test hardware and CCD inspection functions can be configured from the agreed product requirements. Each test requires defined limits and acceptance rules.
When several connector models are required, the machine can be assessed for interchangeable fixtures, recipes, tools, and feeding components. Changeover scope depends on the difference between product models.
The final handling and packaging process can be adapted to the required presentation, quantity, orientation, and downstream logistics.
Machine control, production recipes, user permissions, inspection records, alarm handling, data storage, and MES communication can be configured for the factory environment.
Connector drawings, component drawings, samples, the bill of materials, and technical specifications are reviewed to identify the required assembly and inspection operations.
The production sequence is divided into feeding, assembly, forming, cutting, cleaning, testing, inspection, reject handling, and packaging stages.
Each operation is matched with the required fixture, tooling, actuator, sensor, camera, electrical tester, robot, and control logic.
Actual components are used to evaluate feeding orientation, assembly behavior, tooling contact, visible inspection features, and the required production cycle.
Output, utilization, product checks, data records, changeover requirements, and other acceptance items are defined according to the approved project scope.
CO-SHINING is the automation equipment brand of Dongguan Zhongyao Automation Equipment Co., Ltd. The company has developed and manufactured automation equipment since 2009, focusing on wire harness processing and connector assembly and testing systems.
Its manufacturing resources include an approximately 8,000-square-meter production workshop, more than 60 units of processing equipment, and a team of more than 200 people working across research, development, production, and related technical functions.
Mechanical design, component processing, assembly, control development, testing, and production-line integration are organized around the requirements of each connector project.
Provide connector and component drawings, the bill of materials, physical samples, the required assembly sequence, dimensional tolerances, electrical test specification, visual inspection criteria, target output, and packaging requirements.
Multiple models may be possible when the products share similar components and processing steps. Fixtures, tooling, feeders, recipes, test hardware, and camera settings may need to be changed between models.
The test functions are selected from the connector’s electrical specification. Required test items, limits, test conditions, contact points, cycle time, data format, and pass/fail rules must be defined before the testing system is configured.
CCD inspection can evaluate visible characteristics that can be consistently presented to the camera. These may include missing components, incorrect orientation, pin position, spacing, visible deformation, or an incorrect bending profile.
Reject handling can be configured around the production process. Options may include separation into an NG collection area, process interruption, alarm display, failure recording, or a combination of these controls.
MES connectivity is available. Integration requires confirmation of the communication protocol, data fields, order-management logic, traceability requirements, network conditions, and responsibilities of both systems.
Connector complexity, component-feeding stability, the number of pins, assembly operations, testing time, CCD inspection requirements, reject handling, packaging method, and model changeovers can all affect output.
ZY-CON-401 Connector Automation
Share your connector drawings, component samples, assembly sequence, electrical tests, CCD inspection criteria, target output, and packaging requirements. CO-SHINING will review the tooling, process flow, control system, and data interface for your project.
CCD Inspection
PASSConnector drawings and component samples are recommended for project evaluation.
Samples produced by the equipment
Device features
It can be customized according to requirements.
● The appearance can be customized with an industrial design. The machine cover has access control, which is convenient to operate and safe and beautiful.
● The mechanism design adopts modular, modular and standardized mode, which has been verified to be reliable and stable.
● Standard parts are selected from well-known brands at home and abroad, and servo transmission is preferred for high-speed, quiet and energy-saving.
● It uses intelligent control, combined with CCD camera and robot, with high energy efficiency and high quality to save space.
● The equipment uses the upper computer to collect and detect data, and the production information can be traced, which is convenient for connection with MES.
Equipment parameters
Item | Technical parameter |
|---|---|
Efficiency | ≥2400PCS/H（utilization rate：≥90%） |
Machine functions | Plastic Insulation feeding, contact pin feeding/stitching, contact pin bending, pin header cutting, product cleaning, electrical testing, CCDinspeting, product packaging |
