Ferrite Insertion Tool for Electrical Filter Connectors

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Solution Overview

Problem

The insertion of small ferrite members onto electrical filter connector contacts is a delicate and labor-intensive process due to their size, requiring manual counting, shaking, and precise placement, leading to operator fatigue and inefficiency in high-density connector manufacturing.

Innovation Solution

A method and tool system that uses a ferrite member distribution system with a lock chamber and a vibrating feed bowl to orient and convey ferrite members vertically, allowing controlled insertion onto contact pins, reducing manual effort and improving assembly efficiency by enabling one-by-one placement and rate-controlled distribution.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual shaking and tweezers are used to insert ferrite members, then the small size of ferrite members allows precise placement, but operator fatigue increases and productivity decreases

Engineering Contradiction:

Improveplacement precisionVSAvoidassembly speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The device segments the insertion process into distinct functional zones: a vibrating feed bowl for orientation and initial positioning, a lock chamber for controlled storage, and a distribution system for precise delivery to each contact pin. This segmentation automates the previously manual shaking and picking operations, maintaining precision while eliminating operator fatigue and increasing throughput

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The lock chamber acts as an intermediary mechanism between the feed bowl and the contact pins. It dynamically stores oriented ferrite members and releases them one at a time through a distribution plate, mediating the flow from bulk storage to precise individual placement without requiring manual intervention at each step

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If manual counting and preparation of ferrite members is performed, then the correct number of members can be ensured, but the process becomes labor-intensive and time-consuming

Engineering Contradiction:

Improvecomponent matching accuracyVSAvoidpreparation time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs self-counting and self-preparation through the vibrating feed bowl and lock chamber mechanism. The bowl automatically orients and feeds the exact number of ferrite members needed, and the lock chamber dynamically stores and releases them in controlled quantities, eliminating the need for manual counting and preparation while ensuring accuracy

Inventive Principle:

Principle #25Self-service

3Stability of the object's composition

If repetitive shaking and vertical positioning operations are performed manually, then ferrite members can be oriented correctly, but operator tiredness increases due to small repetitive movements

Engineering Contradiction:

Improvevertical orientationVSAvoidoperator comfort

Core Design Contradiction:

Stability of the object's compositionVSEase of operation

Solution Approach 1:

The manual mechanical shaking and positioning operations are replaced by an automated vibrating feed bowl mechanism that uses controlled vibrations to orient ferrite members vertically and feed them into the lock chamber. This substitution eliminates the need for operators to perform repetitive small movements, reducing fatigue while maintaining proper orientation

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Facilitates easier and more efficient insertion of ferrite members onto electrical filter connector contacts, reducing operator fatigue and improving assembly precision and speed by automating the orientation and placement process.

Implementation Method 1

the ferrite members can be oriented and conveyed using a known vibrating feed bowl

Methodology Applied

Scientific EffectVibration: Vibration

Implementation Method 2

the lock chamber located at the inlet to the distribution system dynamically stores the ferrite members in the vertical position

Methodology Applied

Scientific EffectGravity: Gravitation

Data Source

PatentUS8826522B2Method and set of tools for inserting ferrite members onto electrical filter connectors

Publication Date: 2014.09.09 SOURIAU & CO

AI summary

A method for the insertion of ferrite members onto pins acting as the contacts of an electrical filter connector. The ferrite members are oriented to a desired orientation by a known method. The ferrite members are preferably oriented in the vertical position for storage and are conveyed to a dynamic storage lock chamber equipped with a ferrite member stopping mechanism. A ferrite member distribution system incorporating a horizontally moving distribution plate individually releases the ferrite members from the lock chamber into the distribution system and inserts ferrite members onto the contacts according to a rate controlled by the operator.