This is an off-the-shelf machine purchased by Vevor, a US based distribution company. The machine originally had many defects and loose parts which was likely attributed to shipping conditions. As a result, getting the machine functional involved an arduous process of trial and error in order to find the correct calibration window for the machine. 

In order to automate the cutting and stripping of wires, an overhead assembly is built over the control surface with interfaces for solenoids to make contact with the necessary buttons at the command of our Arduino control unit.

Following the cutting and stripping of wires, the wire segment must be precisely translated to the input of the crimping assembly. This conveyor belt is constructed using a steel plate, two track roller bearings, and two custom belts that interact with the knurled rollers built into the machine. The assembly also features two FDM-printed belt aligners to mitigate the belt's travel during operation. 

Using Hooke's Law and the filament datasheet, we were able to calculate the worst-case force exerted on the roller bearings. Finite Element Analysis was then conducted to find the stress, factor of safety, and deformation of the plate when experiencing the force from the belts. The plate indicated a minimum factor of safety of 3.4.

 The calculations and filament datasheet are shown below.