Electrical Cable Assembly Positioning via Sleeve Reference Measurement
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Solution Overview
Problem
The assembly of electrical cables faces challenges in maintaining precise tolerances, leading to fluctuating assembly quality and increased production costs due to high demands on robustness, safety, and data rate in automotive and autonomous vehicle applications.
Innovation Solution
A measurement method is introduced where the end of a supporting sleeve on the electrical cable is brought to stop against a reference stop, allowing for the detection of the axial spacing between the inner conductor part and the reference stop, which is then used to derive the terminal spacing between the inner conductor part and the supporting sleeve.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional assembly methods are used without measurement, then production speed is maintained, but manufacturing precision deteriorates leading to fluctuating assembly quality
Solution Approach 1:
The patent applies preliminary action by measuring the terminal spacing of the cable assembly before the crimping operation. The measurement arrangement determines the actual terminal spacing between the inner conductor contact element and the supporting sleeve end, allowing the system to pre-calculate the required correction amount. This preliminary measurement enables subsequent compensation during the crimping process, ensuring precise terminal spacing is achieved even when initial assembly variations exist.
2Manufacturing precision
If tight tolerance ranges are enforced to ensure quality, then manufacturing precision is improved, but device complexity increases due to additional measurement and compensation mechanisms
Solution Approach 1:
The patent implements feedback by using the measurement arrangement to detect the actual terminal spacing of each cable assembly, then feeding this information back to the crimping system. The control unit processes the measured value and adjusts the crimping position accordingly, creating a closed-loop control system. This feedback mechanism ensures that each assembly is corrected based on its specific measurements, maintaining tight tolerances without requiring overly complex pre-positioning mechanisms.
3Manufacturing precision
If manual inspection and removal of non-conforming products is used, then manufacturing precision is maintained through quality control, but productivity decreases due to rework and scrap
Solution Approach 1:
The patent applies preliminary action by performing automated measurement and compensation before the crimping operation completes. Non-conforming assemblies are identified through the measurement arrangement, and the control unit automatically adjusts the crimping process or flags the assembly for correction. This preliminary detection and automatic compensation prevent defective products from proceeding to final assembly, eliminating the need for manual inspection and rework while maintaining high quality standards.
Data Source
AI summary
A measurement method for producing an electrical cable wherein an end-side end of a supporting sleeve that is secured to the electrical cable is brought into contact with a reference stop of a reference device. An axial distance between the end-side end of the supporting sleeve and an inner conductor part secured to an inner conductor of the electrical cable and the reference stop is detected, and a connection distance (y) between the front end of the inner conductor part and the end-side end of the supporting sleeve, facing the inner conductor part, is derived from the axial distance.