Insertion Lug Design for Sealing Mat Protection
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Solution Overview
Problem
Existing devices for equipping connector housings with sealing mats and ready-made cable ends often damage the sealing mats, especially when handling thin cables, and are not suitable for processing cables with different diameters.
Innovation Solution
A device with a cable gripper featuring an insertion lug with a widened tip that can be easily guided through the sealing mat's cable passage openings, minimizing stress on the sealing mat and allowing for the handling of various cable diameters, includes a shank thinner than the tip and a conically tapered front area for efficient penetration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If an insertion lug is used to guide the cable through the sealing mat, then the assembly process is simplified, but the sealing mat is excessively stressed or damaged
Solution Approach 1:
The insertion lug is designed with a differentiated structure: a thicker tip region for penetrating the sealing mat and a thinner shank region for guiding the cable. This local variation in cross-sectional dimensions allows the tip to distribute stress over a larger area during penetration, preventing damage to the sealing mat while maintaining ease of assembly.
2Extent of automation
If a cable gripper with insertion lug is used, then cable insertion is automated, but thin cables buckle and cannot be handled properly
Solution Approach 1:
The insertion lug provides mechanical support to the cable from the front side before the cable enters the connector housing. This preliminary support prevents thin cables from buckling during the automated insertion process, allowing the cable to maintain its structural integrity throughout the assembly operation.
3Productivity
If a standardized assembly device is used, then production efficiency is high, but the device is not suitable for processing cables with different diameters
Solution Approach 1:
The cable gripper and insertion lug assembly is designed with adjustable parameters that allow adaptation to different cable diameters. The gripper can accommodate varying cable sizes while maintaining proper gripping force, and the insertion lug's geometry can be adjusted to match different cable passage openings, enabling the same device to efficiently process multiple cable types.
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
A device for inserting pre-assembled cable ends (12) of cables (6) into connector housings (11) provided with sealing mats (8) comprises an insertion unit (2) with a cable gripper (3) having an insertion lug (5). The cable ends (12) can be inserted into the connector housing (11) with the insertion unit (2), the sealing mats (8) having cable passage openings (27) into which cables (6) can be received in a sealing manner. The insertion lug (5) can be guided through one of the cable passage openings (27) of the sealing mat (8) during the insertion process. The insertion lug (5) has a shaft (9) and a flared tip (7).