Modular Coaxial Plug Segmentation for Automated 90-Degree Assembly
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Solution Overview
Problem
Conventional methods cannot efficiently produce 90° angle plugs, which are single-piece components, making them difficult to process automatically and requiring manual handling, and they are laborious to pack and arrange for processing.
Innovation Solution
A modularly configurable plug method involving a cable section and interface section with interchangeable lengths and shapes, where the cable section is adapted to the cable diameter and the interface section is connected to form a coaxial plug, allowing for automated processing using conventional applicators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional single-piece 90° plugs are used, then the plug forms a compact angle connection, but the entire plug must be exchanged for any changes and cannot be automatically processed with conventional applicators
Solution Approach 1:
The plug is divided into multiple separable components including a cable section with cable contact and cable insulator, and an interface section with interface contacts and interface insulator. This segmentation allows individual components to be manufactured separately using conventional applicators and then assembled, enabling automated processing while providing flexibility to change only specific sections rather than the entire plug.
2Strength
If single-piece 90° plugs are manufactured, then the structural integrity is maintained, but manual handling and laborious packing are required
Solution Approach 1:
By segmenting the plug into cable section and interface section that can be manufactured separately and then connected, the invention enables automated processing of individual components using conventional applicators. The cable section and interface section are designed with connection features that ensure structural integrity when assembled, eliminating the need for manual handling while maintaining strength through proper connection design.
3Extent of automation
If modular interface sections with interchangeable lengths and shapes are used, then automated processing with conventional applicators is enabled, but the assembly complexity increases
Solution Approach 1:
The cable section is designed with a universal connection interface that can accommodate different interface section configurations (various lengths and shapes). This universal cable section design allows conventional applicators to process the standard cable section while interchangeable interface sections are added as needed, enabling automated processing without requiring complex assembly mechanisms for each variation.
Solution Approach 2:
The modular design separates the invariant cable section from the variable interface section. The cable section with its standardized structure can be manufactured and processed automatically using conventional applicators, while the interface section with interchangeable lengths and shapes is designed as a separate module that connects to the standardized cable section, reducing overall assembly complexity.
Data Source
AI summary
A method for producing a modularly configurable plug comprises inserting a cable insulator in a pre-shaped outer cable contact, positioning an inner cable contact of a cable in the cable insulator, and bending the pre-shaped outer cable contact to form a cable section. The cable section is adapted to a diameter of the cable and a diameter of the inner cable contact. The method further comprises positioning an inner interface contact in an interface insulator and inserting the interface insulator in an outer interface contact to form an interface section. The interface section is connected to the cable section. The interface section has one of a plurality of different lengths or one of a plurality of different shapes interchangeably connected to the cable section.