Flat Cable-to-Connector Interface for Automated Wire Assembly
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Solution Overview
Problem
The existing methods for connecting wires to connectors, such as plugs and sockets, are time-consuming and costly due to the need for manual soldering of loose wires, which hinders automation and increases manufacturing costs.
Innovation Solution
A method involving a sheet of wires arranged flat with an interface having flexible and rigid parts with conductive tracks and pads, allowing for simultaneous connection and shaping to match the connector form, using crimping or soldering for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual soldering of loose wires is used, then connection reliability is achieved, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by pre-arranging wires in a sheet configuration with predetermined positions before the connection process. This allows wires to be positioned and prepared in advance, enabling automated pick-and-place machines to efficiently transfer them to the connector without requiring time-consuming manual positioning and soldering of loose wires during assembly.
Solution Approach 2:
The patent merges multiple wires into a single sheet structure where wires are arranged side-by-side in a organized manner. This consolidation allows all wires to be handled as a unified component rather than individual elements, enabling simultaneous placement and connection of multiple wires through automated processes, thereby dramatically improving manufacturing productivity.
2Manufacturing precision
If manual wire connection is performed, then connection precision is maintained, but labor cost and time consumption increase
Solution Approach 1:
The sheet structure pre-establishes the spatial relationships and positions of all wires relative to each other and to the target contact locations. This preliminary positioning ensures that when wires are transferred to the connector, their alignment with contacts is predetermined and maintained, achieving manufacturing precision without requiring manual adjustment during assembly.
Solution Approach 2:
The wire sheet acts as an intermediary carrier that maintains precise wire positions during handling and transfer. This intermediate structure allows automated equipment to manipulate the wires as a stable unit, ensuring alignment precision is preserved throughout the manufacturing process while enabling high-speed automated operations.
3Adaptability or versatility
If loose wires are used for connection, then flexibility in positioning is achieved, but automation becomes difficult and costly
Solution Approach 1:
The patent resolves this contradiction by pre-organizing wires into a sheet with fixed positions that provide both stability for automation and adaptability for different connector configurations. The sheet structure maintains wire positions in a controlled manner that allows automated systems to reliably grasp and place wires, while the overall sheet design can be adapted to accommodate various connector types and wire arrangements.
Data Source
AI summary
The invention concerns a method for connecting a cable (4) to a connector part, such as a plug or socket, with electrical contacts (21). The cable comprises at least one layer (41) comprising several wires (42) arranged next to each other, the connector part comprising an interface (10, 60) with tracks for electrically connecting the wires of the layer (41) to the electrical contacts (21), and, when the wires of the layer are connected to the interface (10, 60), the layer is arranged flat. The invention also relates to the products obtained by the method.