Joining Aid for Twisted Electrical Line Housing Insertion
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Solution Overview
Problem
In technical applications such as wiring harnesses for vehicles, it is challenging to maintain the desired alignment, orientation, and position of electrical cables during the insertion of contact part housings, especially when twisting multiple cables, as the cables tend to untwist and change their alignment, orientation, or position, leading to interference issues.
Innovation Solution
A method and device using a joining aid with a base body having open sides and cavities to hold the electrical line ends in a specific orientation, preventing rotation and allowing for twisting and subsequent insertion into contact part housings while maintaining the desired position and orientation, utilizing a gripping device for automated processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If multiple electrical cables are twisted together to reduce interference, then electromagnetic interference is reduced, but the cables tend to untwist during processing, changing their alignment, orientation, and position
Solution Approach 1:
The joining aid is prepared in advance with cavities designed to receive and hold the twisted cable ends. The cavities are pre-configured with appropriate dimensions and orientations to maintain the twisted state of the cables during the entire processing operation, preventing untwisting before the cables are secured in their final positions.
Solution Approach 2:
The joining aid acts as an intermediary device between the twisted cables and the contact part housing. It temporarily holds the cables in their twisted configuration, maintaining their alignment and orientation, and facilitates their transfer into the housing without allowing them to untwist or change position during the processing operation.
2Productivity
If automated processing is implemented for inserting contact part housings, then productivity is improved, but maintaining the desired alignment and position of electrical cables becomes more difficult
Solution Approach 1:
The joining aid is designed to automatically maintain the alignment and orientation of the cable ends through its cavity structure. The cavities provide self-aligning features that guide the cables into the correct positions and maintain them there during automated transfer operations, eliminating the need for complex external alignment mechanisms.
Solution Approach 2:
The patent replaces complex mechanical alignment and positioning systems with a simpler cavity-based holding system. The cavities in the joining aid provide the necessary mechanical constraints to maintain cable alignment and orientation through their geometric design, rather than requiring active mechanical adjustment mechanisms during automated processing.
3Manufacturing precision
If a joining aid with cavities is used to hold electrical line ends, then alignment and orientation are maintained, but the device complexity increases
Solution Approach 1:
The joining aid is segmented into multiple cavities, each designed to hold a specific cable end. This segmentation allows each cavity to be independently optimized for holding and aligning individual cables, while the overall structure remains a single integrated component that can be easily manufactured and reused.
Solution Approach 2:
The joining aid is designed as a universal fixture that can accommodate multiple different cable configurations and types through its multiple cavities. The same joining aid can be used for different cable assemblies by simply placing the cables into the appropriate cavities, eliminating the need for multiple specialized holding devices.
Data Source
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AI summary
A method for the automated processing of at least one electrical conductor (200) is proposed, comprising the steps of: inserting a first end of the electrical conductor (200) into a joining aid (300) from a first side of the joining aid (300), transferring the first end of the electrical conductor (200) from a second side of the joining aid (300) different from the first side into a contact part housing (400), wherein the electrical conductor (200) is held during the transfer by the joining aid (300) and/or the contact part housing (400).