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To solve the problem of low efficiency involved in manually inserting power sockets into soft wires, a new system called an automatic insertion wire device of mechanical arm as a part of intelligent agents has been designed. It has a manipulator end lead channel actuator, a two-degree-of-freedom manipulator, a scissor bending mechanism and a control system. A coordinate system has been established for kinematics analyses and inverse kinematics solution. The joint angles of the manipulator when reaching the terminal hole of the power socket are 47.7° and 91.3° for joint angles 1 and 2, respectively. The motions of the scissor bending mechanism are analyzed using a coordinate system, and the rotation angle of support rod 1 is found to be 32.3° after the completion of soft wire bending. A model of the actuator and scissor bending mechanism is created using SolidWorks, and motion simulations are carried out to verify the insertion of soft wire. A prototype is built and tested, which demonstrates that the angle variation range of the soft wire head part due to push block movement is between 58° and 63°, while the angle variation range of the shear fork bending mechanism to other parts of the soft wire is between 168° and 173°. All parameters meet the anticipated goal, effectively resolving the problem of low efficiency.
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