Coaxial Cable Shield Folding and Stop Sleeve Positioning
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Solution Overview
Problem
The increasing demand for high-frequency coaxial cables with precise connectors to minimize transmission losses and interference, while maintaining low production costs and high production volumes, is challenging due to stringent tolerance requirements and high reject rates.
Innovation Solution
A method and device for processing coaxial cables that involves folding the shielding over the cable end, inserting the inner conductor into a stop sleeve with the shielding pressed against its wall, connecting the inner conductor to a contact using a crimping tool, measuring the distance, and optionally shortening the conductor, which ensures precise positioning and minimizes errors by maintaining the cable end within the stop sleeve throughout the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If stringent tolerance ranges are observed to minimize transmission losses and interference, then manufacturing precision is improved, but productivity decreases due to higher reject rates
Solution Approach 1:
The cable end is pre-inserted into the stop sleeve before connector installation, establishing a fixed reference position in advance. This preliminary positioning action ensures that subsequent connector installations start from a known, precise location, reducing cumulative tolerance errors while maintaining efficient production flow
Solution Approach 2:
The stop sleeve acts as an intermediary component between the cable end and the connector. It provides a stable reference surface and positioning structure that mediates the connection process, ensuring consistent alignment and reducing variability in connector installation precision
2Manufacturing precision
If ever smaller tolerance ranges are observed to reduce imperfections, then manufacturing precision is improved, but device complexity increases due to additional positioning measures
Solution Approach 1:
The positioning function is extracted from the complex multi-step positioning system and consolidated into the simple stop sleeve structure. The stop sleeve alone provides the reference surface and positioning constraints, eliminating the need for additional positioning devices and reducing overall system complexity while maintaining precision
3Manufacturing precision
If additional positioning measures are implemented to maintain precision, then manufacturing precision is improved, but device complexity and processing time increase
Solution Approach 1:
Multiple positioning functions (reference surface, alignment guide, depth stop) are merged into the single stop sleeve component. This consolidation eliminates the need for separate positioning devices and operations, reducing processing time while maintaining the required precision for connector installation
Data Source
Figure 1
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AI summary
The present invention comprises a method for processing a cable (1), in particular a coaxial cable, which has at least one inner conductor (2) and a shield (3) surrounding the inner conductor (2), wherein the method comprises at least the following steps: folding the shield (3) at a cable end (4) and away from the cable end (4); inserting the cable end (4) into a stop sleeve (5), wherein the inner conductor (2) is passed through the stop sleeve (5) while the folded shield (3) is pressed with an end face (6) against a wall (7) of the stop sleeve (5); connecting the exposed inner conductor (2) to an inner conductor contact (8) while the cable end (4) is arranged in the stop sleeve (5); Measuring the greatest distance (a) between an end (9) of the inner conductor contact (8) facing away from the cable end (4) and the end face (6) of the shield (3) while the cable end (4) is positioned in the stop sleeve (5).Furthermore, the invention includes a device for carrying out such a method.