Cable Insertion Guide With Elastic Locking for Clamp-Free Crimping
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Solution Overview
Problem
The existing connector manufacturing process requires a cable clamp to secure the cable during crimping, increasing installation steps and reducing manufacturing efficiency.
Innovation Solution
A cable insertion device comprising a first block with slots, a second block with upper semicircular holes, and a third block with lower semicircular holes, combined into guide holes for cable insertion, and a locking component with elastic cantilevers to prevent cable pull-out, eliminating the need for a cable clamp.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a cable clamp is used to secure the cable during crimping, then the cable remains stationary, but the installation steps increase and manufacturing efficiency decreases
Solution Approach 1:
The cable clamp function is merged with the cable insertion device by integrating elastic cantilevers directly into the insertion device structure. The elastic cantilevers are positioned to contact and secure the cable during insertion, eliminating the need for a separate cable clamp component while maintaining cable stationarity throughout the crimping process.
Solution Approach 2:
The cable insertion device is designed to perform multiple functions: guiding the cable through the housing, securing the cable in position, and maintaining cable stationarity during crimping. The elastic cantilevers provide both guidance and clamping functions, making the device universal and eliminating the need for separate dedicated cable clamp components.
2Reliability
If a cable clamp is used to secure the cable, then the cable is held firmly, but the device complexity increases
Solution Approach 1:
The cable securing function is merged into the cable insertion device structure. The elastic cantilevers are integrated as part of the insertion device, combining the insertion and securing operations into a single integrated tool, thereby reducing device complexity and installation steps.
Solution Approach 2:
The elastic cantilevers automatically engage and secure the cable during the insertion process itself. The cable insertion action triggers the elastic cantilevers to contact and hold the cable, making the securing function self-activating and eliminating the need for separate manual clamping steps.
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 cable insertion device simplifies the connector manufacturing process by securely holding the cable without a clamp, thereby reducing installation steps and enhancing manufacturing efficiency.
Implementation Method 1
a locking component clamped between the first block and the third block and having elastic cantilevers corresponding to the slots. Each of the elastic cantilevers extends into one of the slots and rests against the cable inserted into the cable hole
Data Source
AI summary
A cable insertion device includes a first block having a row of slots and a second block assembled onto the first block. A row of upper semicircular holes corresponding to the row of slots is formed on the second block. The cable insertion device includes a third block assembled onto the first block. A row of lower semicircular holes corresponding to the row of slots is formed on the third block. One of the upper semicircular holes and one of the lower semicircular holes are combined into a guide hole for guiding a cable into a cable hole of a connector housing. The cable insertion device includes a locking component clamped between the first block and the third block and having elastic cantilevers corresponding to the slots. Each of the elastic cantilevers extends into one of the slots and rests against the cable inserted into the cable hole.