Cable Terminal Insertion Fixture for Damage-Free Housing Assembly
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Solution Overview
Problem
Manual insertion of dual-core cable assembly terminals into connector housings is inefficient and prone to terminal or core wire damage.
Innovation Solution
An insertion device comprising a cable control module with terminal and core wire clamping devices, and a housing control module with a housing clamping device, which guides and secures the terminals and core wires during insertion, ensuring precise and damage-free insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual insertion method is used, then device complexity is reduced, but productivity is lowered and reliability deteriorates due to terminal or core wire damage
Solution Approach 1:
The insertion device is divided into distinct functional modules: a cable control module with terminal clamping device and core wire clamping device, and a housing control module with housing clamping device. Each module independently performs specific tasks (clamping terminals, clamping core wires, holding housing), allowing complex insertion operations to be broken down into manageable segments that improve productivity without overwhelming complexity
Solution Approach 2:
The insertion device acts as an intermediary tool between the operator and the cable assembly/housing system. It provides controlled clamping and guiding functions that mediate the insertion process, preventing direct manual handling damage while maintaining operational efficiency
2Reliability
If manual insertion method is used, then device complexity is reduced, but reliability deteriorates due to terminal or core wire damage
Solution Approach 1:
The terminal clamping device and core wire clamping device perform preliminary clamping actions on the terminals and core wires before insertion. This preliminary securing prevents damage during the insertion process by maintaining proper tension and positioning, thereby improving reliability without requiring overly complex protective mechanisms
Solution Approach 2:
Separate clamping devices are provided for terminals and core wires, allowing each to be clamped and protected independently. This segmentation enables precise control over each component's integrity during insertion, improving reliability through targeted protection rather than generic complex mechanisms
3Productivity
If automated insertion device is used, then productivity is improved, but ease of operation deteriorates due to complex device structure
Solution Approach 1:
Multiple clamping and holding functions are merged into an integrated insertion device structure. The cable control module and housing control module work together as a unified system, combining terminal clamping, core wire clamping, and housing holding functions into one coordinated mechanism that improves productivity while maintaining operational simplicity through unified control
Data Source
AI summary
An insertion device for inserting a cable assembly into a housing comprises a cable control module and a housing control module. The cable control module includes a terminal clamping device adapted to clamp to two terminals of the cable assembly, and a core wire clamping device adapted to clamp to two core wires of the cable assembly on which the terminals are crimped. The housing control module includes a housing clamping device adapted to hold the housing while the two terminals are inserted into the housing.