Cable Connector Assembly with Pre-Assembled Conductor Positioning

Solution Overview

Problem

The assembly process of cable plug connectors is complex and costly due to the need for precise tolerances and high mechanical and electrical demands, particularly in the automotive industry where reliability and safety are paramount.

Innovation Solution

A method and apparatus for assembling a cable plug connector that involves prefabricating the electrical cable with an inner conductor part, inserting the insulation part into the outer conductor part, and synchronizing the assembly steps in a time-restricted continuous flow production to reduce costs and improve efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional assembly processes are used for cable plug connectors, then mechanical robustness and electrical reliability can be achieved, but the production cost increases and manufacturing complexity increases

Engineering Contradiction:

Improveplug connection reliabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent applies preliminary action by pre-assembling the insulation part with the inner conductor part before inserting them into the outer conductor part. This pre-assembly ensures precise positioning and tolerance alignment, guaranteeing reliable electrical connection while simplifying the overall manufacturing process. The inner conductor part is pre-positioned within the insulation part with defined axial and radial alignment, eliminating the need for complex post-assembly adjustments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the cable plug connector assembly into distinct modules: the outer conductor part, the insulation part with pre-positioned inner conductor part, and the cable assembly. This segmentation allows each component to be manufactured and prepared separately with controlled tolerances, then assembled in a simplified sequence that maintains high reliability while reducing manufacturing complexity and cost.

Inventive Principle:

Principle #1Segmentation

2Strength

If traditional assembly processes are used for cable plug connectors, then mechanical robustness can be achieved, but the assembly process complexity increases

Engineering Contradiction:

Improvemechanical robustnessVSAvoidassembly process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies preliminary action by pre-assembling the insulation part with the inner conductor part before inserting them into the outer conductor part. This pre-assembly ensures precise positioning and tolerance alignment, guaranteeing reliable electrical connection while simplifying the overall manufacturing process. The inner conductor part is pre-positioned within the insulation part with defined axial and radial alignment, eliminating the need for complex post-assembly adjustments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent merges the insulation part and inner conductor part into a pre-assembled sub-assembly unit. This combination ensures that the inner conductor part is already correctly positioned within the insulation part before insertion into the outer conductor part, thereby maintaining mechanical robustness while significantly reducing assembly process complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Manufacturing precision

If precise tolerances are maintained in assembly steps, then electrical properties and connection quality are improved, but production time increases

Engineering Contradiction:

Improveassembly toleranceVSAvoidproduction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent applies preliminary action by pre-assembling the insulation part with the inner conductor part before inserting them into the outer conductor part. This pre-assembly ensures precise positioning and tolerance alignment, guaranteeing reliable electrical connection while simplifying the overall manufacturing process. The inner conductor part is pre-positioned within the insulation part with defined axial and radial alignment, eliminating the need for complex post-assembly adjustments.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent implements continuous useful action by performing the insertion of the pre-assembled insulation part and inner conductor part into the outer conductor part in a single continuous operation. This eliminates intermediate positioning and adjustment steps, maintaining precise tolerances while maximizing production speed and efficiency.

Inventive Principle:

Principle #20Continuity of useful action

Data Source

PatentUS12212110B2Method and cable fabrication device for assembling a cable connector

Publication Date: 2025.01.28 ROSENBERGER HOCHFREQUENZTECHNIK GMBH & CO KG

AI summary

A method for assembling a cable connector which has an outer conductor part, and insulating part and an electrical cable that is prefabricated with an inner conductor part. In a first method step, the insulating part is introduced into the outer conductor part by relative movement between the insulating part and the outer conductor part. In a second method step, before or at least partially during the first method step, the electrical cable is prefabricated to have an inner conductor part secured on an inner conductor of the cable. In a third method step, during or after the first method step, the prefabricated cable is introduced into the insulating part up to a defined axial terminal position. The positions of the inner conductor part, the outer conductor part and/or the insulating part are fixed relative to each other by compressing the outer conductor part at least partly.