GTI (GUIDED TERMINAL INSERTION SYSTEM)

Producing Quality instead of Testing Quality

The EMDEP Guided Terminal Insertion system (GTI) provides a complete solution for guiding the operator in the process of assembly the wires into the connector. The system guides the operator step by step, indicating the next operation to realize. It includes pick by light guiding for wires, cavity indication by led and full electrical continuity check: Completely guided assembly process free of errors!

Errors Processing

The system is capable to detect the following errors during the assembly process:

  • Electrical test of wire
  • Non continuity (missing wire)
  • Short circuit (wire in wrong cavity)
  • Pull wire operation
  • Excessive pull
  • Unexpected pull

The corresponding error will be displayed on the screen and the LED of the related cavities will be switched on.

Critical errors(excessive pull) block the test, requiring the presence of the supervisor.

GTI2

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Main Features

The following features are supported by the system which is fully customizable according to your process requirements:

  • Part number selection by button or scanner
  • Wire picking guided by LED
  • Wire insertion to connector guided by LED
  • Wire Pull operation (simple or double)
  • Continuity checking or wire presence option
  • 2 Input and 2 output for general purpose
  • Printer supported
  • Unlimited part numbers can be created

Test Mode

Random Selection

Used when the wires are already inserted in one connector and the other end needs to be guided to a main connector.

 

Operator selects randomly the next wire by touching a metal probe, the equipment will indicate the cavity where to insert the wire.

Predefined sequential insertion of wires

Operator follows the process indicated by the equipment.

 

Each wire is requested in a predefined sequence according the data programmed.

Test Modules

The test modules accept different options depending on the guiding and test necessities. The following options can be selected independently and combined in the same station:

Led guiding

Indicates the cavity to insert next wire or affected by the error displayed on the screen

External

Most common option. Led located as near as possible to the connector.

Internal

Located inside the connector shape, the light passes through the cavity of the connector. Fiber optic could be used when there is small cavity or reduced space between them no possibility to use with continuity pins or presence detections.

Lock system

Indicates the cavity to insert next wire or affected by the error displayed on the screen

Pneumatic

Pneumatic clamps locks the connector, normally locked until the test is finished or supervisor cancels the test.

Mechanical

Mechanic clamp is used to hold the connector simplifying the holder concept. The connector can be removed at any time by operator, used normally in combination with auto release option: the lock is automatically released when excessive pull force is applied.

Wire detection

Defines the way in which the equipment will assure the wire presence

Continuity

Continuity pins for each cavity add the possibility to check electrically the wire assuring also the position

Detection switch

Detects the presence of the wire in the cavity. Normally used when only one connector is assembled and it is not required to check the continuity.

None

Used in simple equipment which only guides operator without performing any test.

Wire pull

 Detects the wire pull operation

Pull OK

Give a signal.

Excessive pull

Additional detection activated when excessive pull force has been applied. Used normally for pneumatic locked modules.

Additional detection

Test modules supports additionalstandard detections.

Normally used for detection of spacer open or components

Display

  • TFT display (optional from 7” to 10”)
  • Touch screen
  • Displays detailed information about test, visual aid of connector, color of the wires, etc
  • Suitable to be integrated in the table when assembling big connectors
  • It will replace to the current display (next version)
  • Increase connectivity and processing capabilities for the complete product

Software

The µEditor is a free software developed by Emdep. It gives an easy an intuitive interface to program the part numbers and test options.

 

Download the data to the station connecting to the Ethernet port.

Definition for:

KSK

EMDEP Ksk software implements all the necessary features in order to allow to your line and complete production process to work under ksk system from any car manufacturer:

  • Import final customer data directly. (KBL, DSI, Excel etc…)
  • Sequential test is assured along your production line
  • Production traceability available
  • Complete Harness traceability
  • Possibility to be integrated in your ERP/SAP system