Independent Cable Grips for Offset Plug Housing Assembly
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Solution Overview
Problem
Existing devices and methods struggle to assemble plug housings with prefabricated cable ends of cable harnesses, particularly twisted cable pairs, as individual cables are connected, making it difficult to monitor and correct potential critical segments along the path of travel, such as insertion and sealing mat segments, due to simultaneous passage of cable ends.
Innovation Solution
A device with independently displaceable cable grips allows each cable end to be inserted and passed through critical segments with a longitudinal offset, enabling individual monitoring and correction using force sensors, and optionally vibrating movements to overcome sticking issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple cable ends are inserted simultaneously into plug housing chambers, then assembly productivity is improved, but monitoring precision and reliability of critical segments deteriorate because individual force monitoring becomes impossible
Solution Approach 1:
The patent divides the assembly process into sequential segments by introducing a longitudinal offset between cable ends. Each cable end passes through critical segments (insertion area, sealing mat, restraint devices) at different times, enabling individual force monitoring for each cable while maintaining efficient multi-cable processing capability
Solution Approach 2:
The patent employs displaceable cable grips that can be independently positioned along the longitudinal axis to create and adjust the longitudinal offset between cable ends. This dynamic positioning capability allows the system to optimize both productivity (by processing multiple cables) and measurement precision (by ensuring sequential passage through critical segments)
2Reliability
If cable ends of twisted cable pairs are assembled individually, then force monitoring and correction measures are possible, but assembly time increases due to sequential processing
Solution Approach 1:
The patent implements preliminary action by pre-positioning cable grips with a longitudinal offset before the assembly process begins. This pre-established offset ensures that cable ends will automatically pass through critical segments sequentially during insertion, enabling force monitoring and correction measures without requiring significant additional assembly time
Solution Approach 2:
The displaceable cable grips provide dynamic control over the longitudinal offset, allowing the system to adapt the timing of cable end passage through critical segments. This enables reliable force monitoring while optimizing assembly time by processing multiple cables in an efficient sequential manner rather than strictly one-at-a-time
3Measurement precision
If cable ends pass through critical segments with longitudinal offset, then individual force monitoring is enabled, but device complexity increases due to multiple displaceable cable grips
Solution Approach 1:
The patent applies universality by designing cable grips that serve multiple functions: they grip cable ends, position them with precise longitudinal offset, and enable force monitoring. This multi-functionality reduces the need for separate dedicated components for each function, thereby limiting the increase in device complexity while achieving precise force monitoring capability
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
This approach allows for independent assembly and monitoring of each cable end, ensuring proper locking and reducing assembly errors by allowing individual passage and force measurement through critical segments, enhancing the reliability of the assembly process.
Implementation Method 1
cable grips (10, 20), each having a pair of gripping jaws (11, 12; 21, 22) for gripping one cable end (110, 120)
Implementation Method 2
at least one force sensor for detecting and measuring a force acting on one of the at least two cable ends (111, 121)
Implementation Method 3
optionally vibrating movements to overcome sticking issues
Data Source
AI summary
The present invention relates to a device (1) for assembling at least one plug housing (200) with prepared cable ends (111, 121) of a cable harness (100), in particular a twisted harness comprised of at least two cables (110, 120), wherein the device (1) has at least two cable grips (10, 20) each for gripping one of the at least two cables (110, 120) on a segment (112, 122) of a free cable end (111, 121), in particular untwisted. For selective assembly, in particular for insertion of the cable ends (111, 121) with a longitudinal offset into the plug housing (200) through a segment along the path of travel, which is potentially critical for a successful assembly process, the at least two cable grips (10, 20) are displaceable independently of one another in the longitudinal direction (L) of the cable ends (111, 121) to be gripped.