Cable Manager with Length Pin for Connector Assembly
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Solution Overview
Problem
Conventional connectors require cutting and stripping of electrical wires to specific lengths during assembly, which can lead to faulty connections and inconsistencies, especially in field or on-site assembly.
Innovation Solution
A cable manager with a disc-shaped design featuring axially aligned half-open chambers and a length pin for precise wire alignment and cutting, combined with a contact carrier formed from two half-shells for secure attachment of electrical contacts, ensures accurate wire length and easy assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If electrical wires are cut to specific lengths during field assembly, then the connector can be assembled on-site, but the connections become faulty and inconsistent
Solution Approach 1:
The cable manager is pre-formed with precisely positioned recesses and a length pin that defines the correct wire length. This preliminary preparation of the cable manager allows field assemblers to simply insert wires into the pre-defined positions without requiring precision cutting or measurement skills, thus maintaining manufacturing precision while enabling on-site assembly.
Solution Approach 2:
The cable manager acts as an intermediary component between the wire cutting process and the final connector assembly. It includes a length pin that physically limits wire insertion depth and recesses that guide wire placement, serving as a mediating structure that ensures consistent wire length and positioning without requiring the assembler to perform precise measurements.
2Adaptability or versatility
If electrical wires are manually cut and stripped during assembly, then the connector can be customized for different applications, but the assembly process becomes complex and error-prone
Solution Approach 1:
The cable manager is divided into distinct functional segments: a length pin for defining wire length, multiple recesses for guiding different wires, and integration points for the seal and contact carrier. This segmentation allows the cable manager to handle multiple wires of different lengths and types while presenting a simple, unified interface to the assembler, reducing complexity while maintaining versatility.
Solution Approach 2:
The cable manager serves multiple functions simultaneously: it acts as a wire guide, length reference, organization structure, and alignment feature for the seal and contact carrier. This multi-functionality allows a single component to handle customization needs for multiple wires while simplifying the overall assembly process, as assemblers interact with one universal component rather than multiple separate tools or fixtures.
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The connector (1) has a cable-arranged insert provided for arranging electrical strands within a plug connector housing (2). The cable-arranged insert is provided within the housing in the form of a cable manager for orderly retaining the electrical strands. An axially aligned longitudinal pin is formed at the cable manager. A contact carrier (20) is provided within the plug connector housing for electrical strands and comprises electric contacts (28). The electric contacts are arranged in a center of the contact carrier that is formed of two half shells.