Integrated Light Source Contact Pin for Narrow Grid Assembly
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Solution Overview
Problem
In the manufacturing industry, particularly in the automotive sector, existing contact pin technologies face challenges in simultaneously achieving light-guided contact insertion and electrical testing in narrow grids without requiring process separation, leading to limitations in error detection and assembly efficiency during wiring harness production.
Innovation Solution
Integration of a light source within the contact pin, which includes an electrically activatable illuminant and a light passage channel with entry and exit openings, allowing for direct lighting at the contact point without external light sources, enabling both light-guided assembly and electrical testing in tight spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If external light sources and light guides are used for light-guided contact insertion, then illumination is provided, but space is consumed and process separation is required
Solution Approach 1:
The patent combines the light source, light guide, and contact pin into a single integrated unit. The contact pin serves dual functions: electrical contact and light guidance. The light source is positioned at the tip of the contact pin, eliminating the need for separate external light sources and light guides, thereby removing the requirement for process separation between illumination setup and electrical testing.
Solution Approach 2:
The contact pin is designed to perform multiple functions simultaneously: it provides electrical contact for testing and guides light for visual identification of contact points. This multi-functionality eliminates the need for separate dedicated light guiding components and external illumination systems, reducing device complexity while maintaining illumination capability.
2Quantity of substance
If contact pins are arranged in narrow grids for high-density connections, then connection density increases, but space for external light sources decreases
Solution Approach 1:
The light source is nested within the contact pin structure itself, positioned at the tip or along the shaft of the contact pin. This nesting approach allows the light guiding function to be embedded within the existing contact pin footprint, requiring no additional space beyond what is already allocated for the contact pin in the narrow grid arrangement.
Solution Approach 2:
The patent merges the light source and contact pin into a single integrated component, eliminating the need for separate light guiding elements that would consume additional space. This integration allows high-density contact pin arrangements to maintain light-guided functionality without requiring extra space for external illumination components.
3Area of stationary object
If light sources are integrated into contact pins, then space utilization is optimized, but manufacturing complexity increases
Solution Approach 1:
The contact pin with integrated light source can be manufactured as a modular assembly: the contact pin shaft, light source component, and tip section can be produced separately and then assembled. This segmentation allows each component to be optimized for its specific manufacturing process while simplifying the overall assembly procedure, reducing the complexity burden of integration.
Solution Approach 2:
The integrated contact pin design uses standard, readily available components (contact pin materials, LED or laser diode light sources, optical coupling materials) that can be sourced from existing supply chains. The manufacturing processes for these components are well-established, minimizing the need for specialized or complex manufacturing techniques despite the integrated functionality.
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
This solution optimizes space utilization, allows for simultaneous light-guided contact insertion and electrical testing, enhancing assembly precision and error detection in narrow grids without process separation, thereby improving the efficiency of quality control processes.
Implementation Method 1
at least one light source (15) arranged inside the contact pin (2), which has at least one electrically activatable illuminant (16)
Implementation Method 2
a spring element, in particular a helical spring, is arranged in the casing sleeve, which pushes the contact piston with its contact tip out of the casing sleeve axially
Data Source
Figure 1A~1C
Figure 2A~2C
Figure 2D~2E
AI summary
The invention relates to a contact pin (2), in particular a spring contact pin, comprising a jacket sleeve (4), in which a contact plunger (5) is guided in a longitudinally displaceable manner. At least one light source (15) is provided, which is arranged in the interior of the contact pin (2) and has at least one electrically activatable lighting means (16), wherein the contact pin (2) has at least one light outlet opening (18) for light emitted by the light source (15).