Coaxial Connector Component Assembly for Electric Cables
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Solution Overview
Problem
The automotive industry faces challenges in assembling electrical cables with high-voltage connectors, requiring robust and reliable connections that can withstand high mechanical loads and high voltages, while also needing to be produced economically in large quantities, often relying on manual and complex processes that are prone to errors.
Innovation Solution
A device with an assembly module featuring chambers for connector components, aligned coaxially to guide the cable through connector components, allowing for automated or fully automated assembly, reducing manual intervention and assembly errors, and utilizing an actuator device or production employee to push connector components onto the cable jacket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly processes are used for fitting connector components to cables, then flexibility and adaptability are maintained, but productivity is low and assembly errors increase
Solution Approach 1:
The assembly device is segmented into multiple chambers (first chamber, second chamber, third chamber) that are arranged coaxially. Each chamber can receive and position specific connector components independently, allowing for systematic organization and automated processing of multiple components simultaneously, thereby increasing productivity while maintaining control over the assembly process
Solution Approach 2:
Connector components are pre-positioned in the chambers before the cable assembly process. The chambers are configured to hold connector components in advance, and the cable is then guided through these pre-positioned components, enabling automated assembly without manual intervention during the critical fitting process
2Manufacturing precision
If multiple connector components are fitted sequentially to the cable, then correct ordering is maintained, but assembly time increases
Solution Approach 1:
Multiple connector components are merged into a single coaxial assembly process. The first, second, and third chambers are arranged along a common central axis, allowing multiple connector components to be positioned and assembled simultaneously in the correct sequence as the cable passes through, thereby maintaining precision while reducing assembly time
Solution Approach 2:
The assembly process transitions from sequential linear assembly to radial/coaxial assembly. By arranging chambers in a coaxial configuration around a central axis, the device enables multiple connector components to be positioned and attached in parallel along the cable length, effectively utilizing the radial dimension to reduce the time required for sequential assembly
Data Source
Figure 1~2
Figure 3~4
Figure 5~7
AI summary
The invention relates to a device (15) for manufacturing an electric cable (1), which device is designed in order to fit a cable sheath (4) of the cable (1) with two or more plug-in connector components (10, 11, 12, 13, 14) starting from a front, free end (3) of the cable (1) for subsequently mounting plug-in connectors. The invention provides a fitting module (16) having chambers (17) for receiving the individual plug-in connector components (10, 11, 12, 13, 14) which are arranged in such a way that the plug-in connector components (10, 11, 12, 13, 14) which are received in the chambers (17) form a common channel (K) with a common centre axis (M) in order to pass the cable (7), by way of its front end (3), along the centre axis (M) through the plug-in connector components (10, 11, 12, 13, 14) in order to push the plug-in connector components (10, 11, 12, 13, 14) onto the cable sheath (4) of the cable (1).