Adjustable Connector Conductor for Precision Assembly
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Solution Overview
Problem
Conventional connectors face reliability issues due to manufacturing inaccuracies and age-related precision problems, particularly with conductor length and formation, leading to hindered soldering and increased human error in quality control, which is time-consuming and inefficient.
Innovation Solution
A connector design comprising a connector body, first and second dielectric components, and a conductor component with adjustable features such as snap hook arms and positioning guides, allowing for precise assembly and insulation, enabling reliable electrical connections with coaxial cables while accommodating varying length tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional connectors are manufactured using semi- or fully-automatic machines, then manufacturing efficiency is improved, but manufacturing precision deteriorates due to machine age and wear
Solution Approach 1:
The conductor is designed with adjustability, allowing it to be moved or repositioned within the connector body. This dynamic feature enables the conductor to accommodate variations in length without requiring precise manufacturing tolerances, thus resolving the contradiction between using automated manufacturing (high productivity) and maintaining precise conductor length (manufacturing precision).
Solution Approach 2:
The invention changes the parameter of conductor length from a fixed, precisely controlled dimension to an adjustable parameter. By allowing the conductor length to vary within a range and compensating through adjustment mechanisms, the system can tolerate broader manufacturing tolerances while still achieving reliable connections.
2Manufacturing precision
If manual labor is used to maintain length tolerances and quality control, then manufacturing precision is improved, but productivity deteriorates due to time consumption
Solution Approach 1:
The connector design incorporates self-adjusting features where the conductor can be easily repositioned or adjusted within the connector body. This self-service capability allows the system to compensate for length variations without requiring time-consuming manual measurement and adjustment, thus maintaining precision while improving productivity.
3Ease of manufacture
If the conductor length varies beyond tolerance (>±2 cm), then ease of manufacture is improved, but reliability deteriorates due to hindered soldering
Solution Approach 1:
The adjustable conductor design allows the conductor to be repositioned to achieve proper soldering alignment even when the initial length varies beyond traditional tolerances. This dynamic adjustment capability enables broader manufacturing tolerances (improved ease of manufacture) while maintaining reliable connections (maintained reliability).
Solution Approach 2:
The conductor is pre-positioned or pre-adjusted within the connector body during assembly, allowing for compensation of length variations before the soldering process. This preliminary adjustment ensures that even conductors with varying lengths can be properly aligned for soldering, maintaining reliability while easing manufacturing constraints.
Data Source
AI summary
A connector comprising a connector body, a first dielectric component, a conductor component, a second dielectric component and an inner sleeve is provided. The connector body has a radial front side surface having a plurality of attachment protrusions extended thereon. The first dielectric component has a protruding end portion comprising a first outlet. The conductor component has a conductor body and a conductor strip end, whereby the conductor strip end extends from the conductor body. The first dielectric component is fixed within the connector body, the second dielectric component is fixed within the inner sleeve, and the inner sleeve is fixed within the connector body. The conductor body is fixed within the second dielectric component, inner sleeve, connector body, and first dielectric component, whereby the conductor strip end extends outwardly from the first outlet, and the conductor strip end is fixedly moveable within the first outlet.