Methods and apparatus for manufacturing connectors

Abstract

A method for manufacturing a connector is described, including providing manufacturing data for an insulating body (2) and generating an insulating body having a contact cavity (23) from a material of the insulating body based on the manufacturing data of the insulating body.

Description

Technical Field

[0001] The present invention relates to a method and apparatus for producing connectors. Background Technology

[0002] Insulating bodies for connectors are typically mass-produced using injection molding. Most custom connectors, produced in smaller quantities, are modifications of these injection-molded insulating bodies. Larger, standardized insulating bodies do not utilize all the contact channels within the insulating body for custom contacts. Therefore, the size of the insulating body is larger than actually optimally necessary.

[0003] There is a possibility of automatically ordering, creating, and manufacturing small quantities of connector housings according to these specifications. The insulating body used for these housings is a standard injection-molded insulating body. Summary of the Invention

[0004] The object of this invention is to create a method and apparatus for producing connectors to increase the flexibility of custom design of the insulating body (especially for insulating bodies of smaller batch sizes) that is part of the connector.

[0005] This objective is achieved through the independent method claims and through the device claims. Further advantageous embodiments arise from the dependent claims.

[0006] This document describes a method for manufacturing a connector, the method comprising: providing manufacturing data of a digital twin of an insulating body, and generating an insulating body having a contact cavity from a material of the insulating body based on the manufacturing data of the insulating body.

[0007] Therefore, customized connectors in small batches can be created quickly, flexibly, and cost-effectively to meet customer needs.

[0008] Preferably, the method can be further developed in which manufacturing data is provided individually to the customer via a computer-implemented method using the equipment described below. Thus, by using a computer-implemented method, efficient and proprietary customer designs are quickly and effectively created as digital twins, and then produced and implemented in the desired batch size, without the need for expensive injection molding processes that utilize costly injection molding tools and require lead times.

[0009] According to a further developed method, a contact cavity can be generated by machining a particularly solid blank using cutting manufacturing equipment to produce a custom insulating body with custom coding in the contact surface. The desired shape of the blank has preferably been selected as a standard injection-molded product by a computer-implemented method described below, so that this pre-selected blank is processed in a resource-efficient manner to meet customer specific requirements.

[0010] According to an alternative approach, customer-specific insulation bodies with customer-specific codes in the mating surfaces can be additively produced using additive manufacturing equipment (i.e., by means of 3D printing or selective laser sintering). New materials enabling additive manufacturing are being tested. This saves material and mold resources while creating customized insulation bodies for connectors.

[0011] Alternatively, for larger quantities, injection molding tools manufactured using 3D printing or selective laser sintering can be used to produce custom insulating bodies with custom coding in the contact surfaces. If these specific manufacturing processes are profitable, this allows for cost-effective and time-efficient production of custom insulating bodies.

[0012] To standardize this method as much as possible for cost-effectiveness and time efficiency, solid blanks for custom insulation bodies can be produced by injection molding, wherein, in particular, standardized grounding / protective conductors (i.e., so-called PE connections) can be formed on the blank. The blanks can have various desired standard shapes.

[0013] To ensure connector ease of manipulation and simplified manufacturing, according to further developed methods, contact cavities (especially tapered contact cavities) can be manufactured starting from one side of the workpiece. These contact cavities can be designed for contacts that can be joined (especially by crimping), and can be custom-manufactured individually based on diameter, profile, and depth (especially the diameter, profile, and depth of the lead or tail contacts inside the connector) according to manufacturing data from computer-implemented methods.

[0014] According to a further developed method, the insulating body can be manufactured with contacts, particularly from the machined side of the insulating body having a funnel-shaped contact cavity. This eliminates the need to flip the insulating body inside the equipment for further processing.

[0015] This method can be further developed in which contacts within the insulating body can be set and inserted, meaning they are secured with standardized contact locks, preferably produced by injection molding, and particularly by additive 3D printing. Thus, the contacts within the insulating body are more firmly anchored.

[0016] According to another preferred method, the contact lock can be glued, pressed in, especially tightened with a fixing plate, or clamped with a spring element. These are cost- and time-efficient methods for creating an insulating body and for maintaining or repairing it if necessary.

[0017] Alternatively, at the manufacturer of the insulating body, especially under specific production conditions, the connector can be assembled with the cable connector in the contact cavity of the insulating body in the final assembly equipment. This allows connector manufacturers to focus on the final assembly of connectors with small volume during their production.

[0018] An apparatus for manufacturing connectors with custom insulating bodies having custom contacts is also described herein, and the apparatus is particularly used to perform the methods described above.

[0019] This device can import manufacturing data from the device described below to generate a digital twin, and may include the manufacturing equipment. Therefore, customized insulation bodies can be produced in a resource-efficient manner, and these customized insulation bodies can be made available in a time-efficient manner.

[0020] The equipment described above can be manufactured compactly with a small installation space.

[0021] Alternatively, the equipment can be used in a production line with manufacturing equipment stations, assembly equipment stations, molding equipment stations, and specifically quality control equipment stations. This embodiment is advantageous if a larger quantity is required and more production space is available. According to a further modification of the equipment, the manufacturing equipment can be a CNC machine tool for machining blanks to produce customer-specific insulating bodies from the connector. This means that standard molds can be used to produce customer-specific insulators.

[0022] The apparatus described herein for creating a digital twin of the insulation body for connectors (particularly automatically) includes a computer having a microprocessor, memory, an interface for input, an interface for screen output, an interface for data output, and an interface for bidirectional data and computer networks. The memory includes a computer program product having an interrogation device for technical data about the connector and a CAD design device for the insulation body of the connector. Using the CAD design, a generative design can be automatically generated based on at least one algorithmic device and technical data from the interrogation device, and this generative design can be output as a digital twin via an interface through an output device.

[0023] The inquiry device can be designed in such a way that, based on the connector requirements, customer-specific technical data is requested regarding the number of connector components, the number of connector contacts, the number of power lines and data lines, and their rated power. Power is indicated in volts and amperes. Specifications are provided for the contacts where signals are to be transmitted.

[0024] This means that a device has been created that can produce customized insulation bodies for connectors based on customer-specific technical data through an automated workflow, thereby producing these insulation bodies in a resource-efficient manner and without making them too large.

[0025] According to a more advanced embodiment, the at least one algorithmic device includes at least one algorithm based on the finite element method (FEM) and / or finite element analysis (FEA) and / or an algorithm using an artificial intelligence method with self-learning capabilities and / or neural networks and / or an algorithm for mechanical and / or electrical wiring in CAD applications and / or an algorithm for lightweight construction.

[0026] It goes without saying that these lists should not be interpreted as exhaustive, but rather as encompassing all known technical approaches in the design field that form algorithms for automatically generating CAD designs based on given technical constraints and specifications.

[0027] Therefore, for increasingly smaller quantities, the cost of generating customized designs for the connector's insulation body can be significantly reduced. Consequently, it becomes possible to generate a larger number of CAD designs at a lower cost for selecting customized insulation bodies. Furthermore, resources can be saved regarding materials if the insulation body is constructed to meet the requirements.

[0028] Traditionally, custom connectors undergo one or more different serviceability test procedures. These tests assess whether the insulator / insulator body is adequate for air gaps and creepage distances, pilot contacts and insertion / extraction forces, and whether other tests known in the art meet the necessary requirements (specifically, DIN standards). More recently, these tests can also be simulated using appropriate test equipment.

[0029] Therefore, the computer program product preferably includes a testing device by means of which it is feasible to use a generative design found for a specially customized digital twin of the insulating body to withstand at least one of the following tests with respect to air gap and creepage distance between contacts and / or insertion and extraction force and / or pilot contacts by means of simulation.

[0030] In this way, labor time and other resources are shared between operating times, resulting in significant savings in connector installation and delivery time. Connectors can be delivered to customers faster because the required tests have already been checked in simulations. This means that actual simulations and tests in the testing lab can be eliminated or reduced to a few samples.

[0031] According to another embodiment, the device includes a selection device by means of which different designs of the digital twin of the insulation body can be listed according to certain criteria of the order, particularly according to criteria of ease of assembly, required installation space, weight, CO2 cost, component cost and / or insertion and extraction force.

[0032] It should be understood that these standards are merely exemplary and not exhaustive, and may include other standards known according to existing technology. By selecting equipment, customers can thereby determine the design focus for insulators in a customer-specific manner.

[0033] Insulating bodies are used in connectors, one as a socket and the other as a connecting element. More preferably, to ensure that the combination of the two insulating bodies as a male-female pair always properly mates, the device includes a setting mechanism for generating the male-female pair of the two insulating bodies, which has a Poka-yoke mating connection. The Poka-yoke principle means avoiding unexpected errors during the connection process.

[0034] Preferably, the device further includes manufacturing development equipment, by means of which manufacturing data can be generated from the product data file of the digital twin of the insulating body according to the planned manufacturing process.

[0035] The equipment can import manufacturing data from the product data file of the digital twin of the insulating body according to the planned manufacturing process. For example, manufacturing data can be generated to machine the insulating body from raw materials into a customized insulating body; if such an insulating body is desired, 3D printing data can be created; or for larger quantities, injection molding tools can be generated from the product data of the digital twin of the insulating body, which may come from 3D printed insulating bodies. The manufacturing development equipment preferably selects an appropriate manufacturing process and generates the necessary manufacturing data based on the specified expected customer batch size and other insulating body specifications.

[0036] Furthermore, the equipment includes a certification device that can output certification reports regarding the simulations performed in relation to the selected generative design of the insulation body and / or connector. Therefore, the simulation test reports can be automatically provided to customers for use in custom generative designs, which they can rely on when installing these custom connectors in their specific custom systems.

[0037] An automated system for creating digital twins of insulation bodies for connectors is also described, comprising the device described above, wherein a client computer can access and communicate with the device via its network interface, particularly utilizing an internet connection. Online store devices can also be integrated with or communicate with this device, allowing customers with distributed client computers requiring customized connectors to digitally connect to a central device. Customers can use their client computers to select their desired insulation body design from multiple designs based on their specific technical data. They can order automatically generated and selected insulation body designs from their client computers, with payment processing and settlement preferably handled on the seller's side. This simplifies and automates the process, making the creation of customized, resource-efficient digital twins of insulation bodies for connectors much faster.

[0038] According to the further developed system, the described device is preferably configured as a main device, and the various devices of the computer program product described above are integrated as parts of the computer program product on an additional separate computer. Product documentation and the processing results of the product documentation can be exchanged between the main device and the additional separate computer via a network interface. This allows the resource-intensive parts of the computer program product to remain on the existing installation and potentially integrates third-party providers into the system having the entire computer program product.

[0039] This document describes a computer-implemented method for creating a custom digital twin of an insulating body for a connector, particularly using the apparatus or system described above. The computer-implemented method includes: an inquiry step involving technical data on the contact connections and the desired number of custom connectors; an automatic generation step based on an algorithmic device of a CAD design apparatus and the technical data from the inquiry step, automatically generating at least one design, preferably a further design, of the insulating body using the CAD design apparatus; and providing the digital twin of the insulating body as a product data file at a data interface.

[0040] Using the method described above, at least one design, preferably multiple designs, of a custom insulation body can be automatically generated upon customer request. This automates and combines previously manual activities, resulting in a significant cost reduction for the custom insulation body. Furthermore, the time required to create such a connector is significantly reduced.

[0041] A customized insulating body for connectors (which has been generated as a digital twin using the methods described above, the equipment or system described above, and produced as a physical insulating body using manufacturing equipment) offers customization advantages, such as customization advantages in terms of available space or fixed functions through simulations that have been performed efficiently.

[0042] A connector having the aforementioned insulating body and housing is also described, wherein the housing and / or insulating body are preferably lockable, both of which are designed as a female connector and a male connector.

[0043] Furthermore, preferably, the product data file is generated using the method described above and the equipment or system described above. This product data file includes all commonly expected technical features and a customized, optimized, automatically generated 3D design of the insulation body, preferably with a suitable housing and its connections for cable entry. The product data file may also include manufacturing process information required for machining, injection molding, or 3D printing, as well as their manufacturing tools.

[0044] This objective is also achieved by a computer program product that can be loaded into the computer memory of the device or system described above to execute the methods described above using code commands.

[0045] Therefore, this objective is achieved efficiently and resource-efficiently through a combination of methods that can be integrated into individual devices. Attached Figure Description

[0046] The invention will now be explained in more detail with reference to exemplary embodiments and accompanying drawings, which illustrate: Figure 1 A schematic structure of a device for generating digital twins is shown; Figure 2 Showing from according to Figure 1 A schematic flowchart of the method for implementing a computer program product for a device; Figure 3 A schematic view of the system is shown; Figure 4 , 5 6. Different insulating bodies are shown in perspective view; Figure 7 The equipment used to produce custom connectors is shown; and Figure 8 Showing according to Figure 7 A schematic flowchart of the equipment. Detailed Implementation

[0047] Figure 1 A device 1 is shown for automatically creating at least one digital twin of an insulating body 2 for a customer-specific connector using a computer 3. The computer 3 has a microprocessor 4, a memory 5, an interface 6 for input, an interface 7 for screen output, an interface for data output, and a bidirectional data and computing network 8. The computer memory 5 contains a computer program product 9, which can be loaded and stored in the memory 5 using code commands.

[0048] Computer program product 9 includes query device 10 and CAD design device 11 with algorithm device 12. Query device 10 is designed to collect technical data on customer-specific connectors having customer-specific insulating bodies 2. This technical data includes both the required number of insulating bodies and the number of contacts, as well as the types of contacts related to power and signals. Therefore, the customer provides specific requirements to query device 10, including the number and type of contacts regarding voltage, current, data transmission methods, pneumatics, etc., and possibly even the maximum space required.

[0049] The CAD design device 11 includes a CAD design program with an algorithm device 12 according to the prior art, which generates a generative design based on technical data from the query step 10 using at least one algorithm. An example of such a design of the insulating body 2 is presented as a digital twin in a screen view of a screen 13 connected to a screen output interface 8.

[0050] exist Figures 4 to 6 The example illustrates another generative design of the digital twin of the insulating body 2 for the connector.

[0051] Algorithm device 12 includes algorithms for automatically generating CAD designs based on existing technologies, such as algorithms based on the finite element method (FEM) and / or finite element analysis (FEA), and algorithms using artificial intelligence methods, which may include self-learning functions or neural networks. The algorithms may also include CAD applications for mechanical and / or electrical wiring, as well as other known algorithms, such as those for lightweight or biomimetic lightweight constructions. Therefore, resource-efficient and material-efficient designs can be automatically created as digital twins.

[0052] The computer program product includes a selection device 14 that prompts the customer to select a specific design of the digital twin from a list generated by the customer based on custom criteria such as weight, space, ease of assembly, and component cost, and displayed on screen 13 in order of priority depending on these criteria.

[0053] Prior to design selection, test equipment 15 is provided, which simulates at least one generative design of the digital twin of the insulation body to undergo various tests, particularly tests concerning parameters such as air gaps and creepage distances between contacts, pilot contacts, insertion and extraction forces, or thermal management simulations. Simulated test results may also be provided in the order list or standards. Therefore, test equipment 15 can be placed before or after equipment 14 in this process.

[0054] Similarly, before or after this step, a mechanism 16 is provided for generating error-proof connections to create a socket-plug combination of two insulating bodies, where only the correct connector can be connected and the contacts are always properly aligned. This prevents the plug from being inserted into the socket incorrectly. Alternatively, the contacts in the insulating bodies can be arranged in a manner that allows the insulating bodies to rotate, for example, 180 degrees, and still correctly align the contacts. Device 1 also includes a certification device 17 that generates a certification report on the simulations performed to ensure functionality, and thus results in shortened type testing. This report relates to the customer's selected design for the insulating body 2.

[0055] In the next step, optionally, manufacturing data is generated by manufacturing development equipment 18. The type of manufacturing is selected based on the previously specified desired quantity of the insulating body 2; for example, machining is typically used for small batch sizes, and injection molding is chosen for very large quantities, or a specific 3D printing method may be selected if conditions permit. The manufacturing data is exported from the product data file of the digital twin of the insulating body 2 and digitally appended to the product data file.

[0056] In output device 19, digital data is given to the user or customer in output step 19. Optionally or preferably, this data is also transmitted to online store 20, so that the customer can order this customer-specific insulated body along with the connector directly from online store 20 before receiving the data, and order all necessary components if necessary. Online store 20 can be integrated into device 1, or it can be part of system 100 on a separate online store device. Optionally, the order is immediately forwarded from online store 20 to... Figure 7 The device 700 described herein is used to produce connectors with customer-specific insulating bodies.

[0057] Figure 2 A preferred flow of a computer-implemented process is shown, for example, when the computer-implemented process is loaded into the program memory 5 of device 1 by code commands and run on computer 3 having microprocessor 4, the computer program product 9 executes the computer-implemented process.

[0058] Computer program product 9 begins with a call to A1, or as... Figure 1 As shown, the computer program product is invoked on device 1 via an input interface having keyboard 61, or in system 100, as... Figure 3 As shown, the client computer 50 communicates with the device 1 via a network interface 8, particularly using an Internet connection 40. In this case, the device 10 queries technical data regarding the contact connections of the client-specific insulating body 2, A10.

[0059] Only after all the required data has been entered does the process move to the next step S11, where at least one design, preferably multiple designs, of the customer-specific insulation body 2 is generated using the CAD design device 11 in conjunction with an algorithm based on the algorithm device 12.

[0060] In step S15, the test equipment 15 examines the generative design of the digital twin of the insulating body 2 to ensure its functionality through simulation. These simulations are well known in the art and are incorporated herein. Therefore, physical testing is no longer necessary, thus saving time and resources through computer-implemented simulation.

[0061] In selection step S14, the customer uses selection device 14 to select a specific digital twin design from various designs based on a list generated by the customer in a specific order using custom criteria. Depending on the customer's requirements, these criteria may include aspects such as space, weight, component cost, insertion / extraction force, ease of assembly, and many other criteria.

[0062] In step S16, mechanism 16, used to generate error-proof connections, creates error-proof connectors for the design of the insulating body 2 selected in step S14. This allows only one type of socket-plug combination, thus ensuring that both insulating bodies can be explicitly connected to the correct connector.

[0063] In optional step S17, a certification report is generated by certification device 17, which provides the customer with evidence and written documentation of the defined simulation, thereby allowing the customer to trust the quality of the connector according to the defined certification specifications.

[0064] Optionally, in the next step S18, manufacturing data for the insulating body 2 is generated by the manufacturing development equipment 18, and a specific manufacturing process is selected. Such manufacturing development equipment is well known in the art. The advantage is that the relevant manufacturing data is available immediately after the design of the insulating body 2 is generated, eliminating the need to initiate additional manual processes. Therefore, at the end of the process, both the positive component in digital twin form and the relevant data for its manufacturing are available.

[0065] In output step S19, the customer receives a digital twin of the connector and the customer-specific insulation body in a desired standardized format (possibly a proprietary file format), all of which are automated through numerous process steps and equipment of the computer program product.

[0066] Optionally, in step S20, the purchase price is allocated to the components, meaning that the insulating body 2, along with the entire connector, allows the customer to order the desired quantity of the digital twin physical manufacture of the connector and insulating body 2 directly from the online store 20 (either from their client computer 50 or by an employee using input device 61 upon the customer's request). In this final step, an estimated delivery date can preferably be provided.

[0067] It is important to understand that not all of the steps mentioned need to be part of the computer-implemented process, and the order and combination of the steps can be changed as needed, within the scope of protection.

[0068] Figure 3 System 100 is shown, which is used to automatically create an insulating body 2 for a connector using device 1 as described above and a client computer 50, which naturally includes an input terminal 61 with a screen display 13, which is omitted here for simplicity. The client computer 50 is connected to device 1 via network interface 8 and Internet connection 40, enabling them to communicate.

[0069] System 100 includes device 1 as master device 101, on which only a portion of the steps and devices of computer program product 9 are implemented, as described above. Other portions of computer program product 9 are outsourced to separate computers 60, 70, and are attached and invoked as needed when requested by master device 101 after process steps. Each of these attached computers 60, 70 includes one or more separate devices from computer program product 9. Each of these devices may be a CAD design device 11, a testing device 15, a certification device 17, or an online store device 20.

[0070] Figures 4 to 6 Various perspective views depict a custom insulating body 2 with custom coding within the connector interface of a connector. This custom insulating body 2 is created as a digital twin by device 1 or system 100 and subsequently used as... Figure 7 and Figure 8 The device 700 described herein is manufactured as a physically insulating body 2.

[0071] Figure 7 An apparatus 700 is shown for manufacturing a custom insulating body 2 for a connector having a custom contact 22. The apparatus 700 can perform actions such as... Figure 8 The procedure described in [the document].

[0072] exist Figure 7The device 700 is depicted in a compact design. However, it should be understood that the device 700 can be set up in an extended and stretched form within a manufacturing line in a larger plant, or distributed across multiple workshops.

[0073] Device 700 (specifically device 710) features a network interface 708 for importing manufacturing data of the insulating body 2 as a product data file via a local network or a remote network (such as the Internet 40). The manufacturing data can be imported via, for example... Figure 2 The computer-implemented program shown is from, for example Figure 1 and Figure 3 The device 1 or system 100 shown generates data to create a digital twin of a customer-specific insulation body 2.

[0074] Manufacturing equipment 710 processes the blank based on manufacturing data from equipment 1 to form a completed insulating body 2, used to create a digital twin of the insulating body. The blank is made of solid plastic material, which can be produced by injection molding.

[0075] It is important to understand that there are various standardized forms of blanks. The minimum space blank closest to the desired customer-specific insulation body 2 is provided manually or automatically by storage equipment, the purpose of which is not explicitly stated, for storing and selecting the appropriate blank.

[0076] The manufacturing equipment 710 is preferably a cutting CNC machine 712 with corresponding plastic processing tools. The CNC machine 712 processes the blank from one side, thereby creating a funnel-shaped contact cavity 23. The diameter of the contact cavity 23 increases on the tool side and decreases towards the opposite side of the insulating body 2.

[0077] Contact cavity 23 is machined to a customer-specific code for the mating surface (specifically in terms of depth, diameter, and profile). Contact cavity 23 is manufactured differently depending on the desired type and performance of contact 22, and other manufacturing rules. Contact cavity 23 is manufactured large enough to accommodate contacts that are crimped with cables or wires.

[0078] Preferably, a protective conductor is formed on the blank using equipment not shown.

[0079] The depth of the contact cavity can vary for the pilot contact or the tail contact within the insulating body 2 of the connector.

[0080] After all machining work has been completed in manufacturing equipment 710, the insulating body 2 is transferred from transport equipment 750 to the next and subsequent processing unit by means of clamping arm 755, and each processing unit all the way to the output.

[0081] Following manufacturing equipment 710 is assembly equipment 720. In assembly equipment 720, contact locks 722 are inserted into contact cavities 23. Contact locks 722 may comprise standardized injection-molded components. Contact locks 722 may be press-fitted, screwed in, glued, or attached with retaining plates, particularly by means of spring elements. From transport equipment 750 with transport arms 755, insulating body 2 is transferred to molding equipment 730, where contacts 22 are crimped, meaning cables and wires are connected, and connector housings may be added simultaneously or sequentially.

[0082] For an optional additional step, the quality control device 740 is arranged to inspect the connector for a specific definition of quality characteristics.

[0083] Figure 8 The device 700 is shown according to Figure 7 A schematic procedure for manufacturing a connector with a customer-specific insulating body 2. By means of... Figure 2 The computer-implemented process involves exporting manufacturing data files from a digital twin of a customer-specific insulation body from device 1 and providing them to device 710 as needed via data network interface 708. This may include a first sequence of first process steps S81.

[0084] In process step S81, the equipment 710 produces a customer-specific insulating body 2 with a contact cavity 23 from a plastic preform.

[0085] In the next step S82, the contact lock 722 is inserted into the contact cavity 23 by means of a device for attaching the contact lock. It should be understood that this step is optional and can be performed by the manufacturer of the insulating body or by the customer for the assembly of the device with the insulating body and special connectors.

[0086] In optional step S83, using contact lock 722 and contact 22, insulating body 2 is formed and assembled to connector having housing and cable connection.

[0087] Typically, customers are provided with an insulating body featuring a contact lock and complementary individual contacts for the contact lock, allowing customers to assemble the connector themselves. The cable is usually available to the customer, so the complementary individual contacts are crimped and installed within the insulating body by the customer. The housing can be standardized or customer-specific.

[0088] In optional step S84, the quality characteristics of the connector are checked in optional quality control equipment 740.

[0089] Therefore, customer-specific insulation bodies with minimal footprint or optimized components according to the aforementioned customer-specific characteristics can be efficiently produced, thereby saving resources. Previous variations of systems, methods, and apparatus are provided to better understand the structure, operation, and characteristics of the proposed solutions; they do not limit this disclosure to exemplary embodiments. The accompanying drawings are schematic, in which important features and effects are partially enlarged to illustrate functions, operating principles, technical designs, and features. Any function, principle, technical design, or feature disclosed in the figures or in the text (including all claims, various features in the text, and other figures, other functions, principles, technical designs, and features disclosed in this disclosure) can be freely and arbitrarily combined such that all conceivable combinations of the described solutions are attributed. This includes combinations between all individual embodiments in the text, in each part of the specification, and in the claims, and also includes combinations between different variations in the text, claims, and figures.

[0090] The details of the systems, devices, and methods described above are presented in context; however, they can also be independent and freely combinable with each other. The proportions of the individual components and portions shown in the figures, as well as their dimensions and scales, should not be construed as limiting. Instead, individual dimensions and scales may deviate from those shown. The claims do not limit this disclosure, and therefore do not limit the possibilities of combinations of all disclosed features. All figures are shown only as schematic, non-scaled representations. Furthermore, particular emphasis is placed on the accompanying drawings of the invention.

Claims

1. A method for manufacturing a connector, the method comprising: - Provide manufacturing data for the insulating body (2), - An insulating body with a contact cavity (23) is produced from the material used for the insulating body based on the manufacturing data of the insulating body.

2. The method according to claim 1, wherein, A method implemented by means of a computer for creating a digital twin of the insulating body of a connector, particularly by means of a device (1) for creating a digital twin or a system (100) for creating a digital twin of the insulating body of a connector, the system (100) including the device for creating the digital twin, wherein a client computer (50) is able to communicate with the device via a network interface (8), particularly using an Internet connection (40), the method comprising: - Inquiry steps regarding technical data for contact connections and the expected number of connectors (A10); - A step (S12) of automatically generating at least one design for an insulation body using the CAD design equipment based on the algorithm device of the CAD design equipment and the technical data from the query step; and Provide a digital twin of the insulation body as a product data file at the data interface (S19); and The manufacturing data is provided to a computer (3) from a device (1) for creating a digital twin of the connector's insulation body (2) in a customer-specific manner. The computer (3) has a microprocessor (4), a memory (5), an interface (6) for input, an interface (7) for screen output, an interface for data output, and a bidirectional data and computing network. The memory includes a computer program product (9) having an interrogation device (10) for technical data of the connector and a CAD design device (11) for the insulation body. Using the CAD design device (11), a generative design of the insulation body (2) can be automatically generated based on at least one algorithm device (12) and technical data from the interrogation device, and output as a digital twin from the output device (19) via the interface.

3. The method according to claim 1 or 2, wherein, Contact cavities (23) are generated by machining blanks, especially solid blanks, with customer-specific codes on mating surfaces using machining manufacturing equipment.

4. The method according to claim 1 or 2, wherein, Customer-specific insulation bodies with customer-specific codes in the mating surfaces are generated using additive manufacturing equipment, namely by means of 3D printing or selective laser sintering.

5. The method according to claim 1 or 2, wherein, The customer-specific insulation body with a customer-specific code on the mating surface is produced by an injection molding tool, which is manufactured by 3D printing or selective laser sintering.

6. The method according to claims 1 to 3, wherein, Solid blanks for customer-specific insulation bodies are produced through injection molding processes, particularly by utilizing standardized protective conductors formed on the blank.

7. The method according to claims 1 to 6, wherein, The contact cavity (23) is manufactured starting from one side of the workpiece, particularly a conical contact cavity, wherein the contact cavity (23) is designed for connecting contacts, particularly contacts connected by crimping, and the contact cavity (23) is manufactured according to manufacturing data from the computer-implemented method, particularly for the lead or tail contacts inside the connector, which are manufacturing data in terms of diameter, profile and depth.

8. The method according to claims 1 to 6, wherein, An insulating body for the contact element was manufactured, particularly from the machined side of the insulating body having a funnel-shaped contact cavity (23).

9. The method according to claims 1 to 6, wherein, The contacts of the insulating body are generated using contact locks, which are provided by standardized components, particularly injection-molded components, and are inserted.

10. The method according to the preceding claim, wherein, The contact lock is glued, press-fitted, especially screwed in by means of a fixing plate, or clamped by a spring element.

11. The method according to the preceding claim, wherein, The method includes the step of assembling a connector having a cable connection onto an insulating body in the contact cavity.

12. An apparatus (700) for manufacturing an insulating body (2), particularly a customer-specific insulating body (2), for a connector having a customer-specific contact (22), said apparatus (700) being particularly used for performing the method according to any one of claims 1 to 11, wherein, The device (700) is designed to import manufacturing data from the device (1) for creating a digital twin and includes a manufacturing device (710), wherein the device (1) for creating a digital twin of the insulating body (2) for the connector includes a computer (3) having a microprocessor (4), a memory (5), an interface (6) for input, an interface (7) for screen output, an interface (8) for data output, and a bidirectional data and computing network, wherein the memory includes a computer program product (9) having an interrogation device (10) for technical data of the connector and a CAD design device (11) for the insulating body, wherein the CAD design device (11) enables the automatic generation of a generative design of the insulating body (2) based on at least one algorithm device (12) and technical data from the interrogation device, and outputs it as a digital twin from the output device (19) via an interface.

13. The device according to the preceding claim, wherein, The equipment is arranged in a production line having stations for the manufacturing equipment (710), the assembly equipment (720), the molding equipment (730), and specifically the quality control equipment (740).

14. The device according to the preceding claim, wherein, The manufacturing equipment is a CNC machine used to machine blanks to manufacture customer-specific insulating bodies (2) for connectors.

15. A connector having a customer-specific insulating body (2) generated from a digital twin using a device (1) or system, wherein the customer-specific insulating body (2) is generated as a physical insulating body using a device (700) according to any one of claims 12 to 14.

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