Cable-End Plug Alignment by Contact Carrier Rotation
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Solution Overview
Problem
The alignment of plug connectors at opposite ends of a multiconductor cable is often mismatched due to the lay length of the cable, leading to issues in final assembly as the orientation specification cannot be complied with, resulting in twisted line sets and inability to rotate the plug connector relative to the cable.
Innovation Solution
The method involves rotating the contact holder relative to the electrical conductors during the manufacturing process to correct alignment before crimping the sleeve onto the cable, which reduces the length between the contact holder and the cable end, ensuring proper alignment of plug faces and allowing for correct assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the plug connector is attached to the cable end without rotation, then the manufacturing process is simple, but the alignment of plug faces at opposite ends of the cable is mismatched
Solution Approach 1:
The contact holder is rotated relative to the cable before crimping the sleeve, performing the alignment correction in advance during manufacturing. This preliminary rotation action ensures that the plug faces are pre-aligned to the correct orientation, eliminating the need for post-assembly adjustments and resolving the alignment mismatch problem.
2Manufacturing precision
If the cable length is fixed, then the cable structure is simple, but the plug connectors cannot be aligned due to lay length
Solution Approach 1:
The effective length between the contact holder and cable end is changed by rotating the contact holder, which twists the conductors together and reduces the length. This parameter change in length accommodates the alignment requirement while maintaining the overall cable structure.
3Adaptability or versatility
If the plug connector orientation is fixed to the cable, then the assembly is simple, but the orientation specification cannot be complied with
Solution Approach 1:
The correct orientation is established in advance by rotating the contact holder during manufacturing, before final assembly. This preliminary orientation adjustment ensures that the plug connector meets the required orientation specification while maintaining a simple fixed assembly structure.
Data Source
AI summary
The invention relates to a method for assembling an arrangement (1) of a plug connector (3; 4) comprising a contact carrier (6) at one end of a cable (2), wherein the position of the plug connector (3; 4) is adjusted to the position of the electrical conductors (21, 22) of the cable (2) to which the plug connector (3; 4) is joined before the cable (2) is press-fit with a sleeve (7), which partly encloses the contact carrier (8), during the assembly process by means of correcting the alignment of the plug connector (3; 4). For this purpose, the mounted contact carrier (6) must be rotated relative to the electrical conductors (21, 22); this rotation causes the electrical conductors (21, 22) to be turned over, which leads to a reduction in length between the contact carrier (6) and the end of the cable (2).