Cable Connector Terminal Insertion Depth Detection
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Solution Overview
Problem
Existing cable connector assembly processes lack effective methods to ensure accurate insertion depth of terminals within the housing, leading to potential improper connections due to either too small or too large insertion depths.
Innovation Solution
A detection device comprising a positioning assembly and a detection assembly with a first driving device, sensing element, and displacement sensor, which positions the housing and measures the insertion depth of the terminal by sensing the displacement of the sensing element in contact with the terminal's free end.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If no detection device is used during assembly, then the assembly process is simple and fast, but the insertion depth of the terminal cannot be ensured to be accurate
Solution Approach 1:
The patent replaces complex optical detection systems (lasers, vision systems) with a simple mechanical measurement system consisting of a sensing element and displacement sensor. The sensing element mechanically contacts the terminal's free end, and the displacement sensor measures the mechanical displacement to calculate insertion depth, achieving accurate measurement without complex optical equipment
Solution Approach 2:
The detection device utilizes the terminal's own free end as the measurement reference point. By contacting the free end and measuring its position relative to the housing, the system uses the component itself for measurement, eliminating the need for external complex measurement systems
2Measurement precision
If complex detection systems like lasers or vision systems are used, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent explicitly replaces optical detection systems (lasers, vision systems) with a mechanical measurement system. The sensing element mechanically contacts the terminal and the displacement sensor measures mechanical displacement, achieving the same measurement precision without the complexity and cost of optical systems
Solution Approach 2:
The patent uses a simple, inexpensive mechanical sensing element and displacement sensor combination instead of expensive optical systems. This cheaper mechanical system achieves sufficient measurement precision for the application, reducing both device complexity and cost
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device accurately determines the insertion depth of the terminal, ensuring proper connection by calculating the distance between the terminal's free end and the housing's end, thus preventing connection issues associated with incorrect insertion depths without requiring complex systems like lasers or vision systems.
Implementation Method 1
a displacement sensor mounted on the first driving device and movable in a moving direction of the sensing element by the first driving device. The displacement sensor is connected to the sensing element and senses a displacement of the sensing element
Data Source
AI summary
A detection device for detecting an insertion depth of a terminal of a cable connector inside a housing of the cable connector includes a positioning assembly and a detection assembly. The positioning assembly positions the housing of the cable connector. The detection assembly includes a first driving device, a sensing element mounted on the first driving device and movable by the first driving device, and a displacement sensor mounted on the first driving device and movable in a moving direction of the sensing element by the first driving device. The displacement sensor is connected to the sensing element and senses a displacement of the sensing element.