Modular Assembly Device for Electrical Connectors
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Solution Overview
Problem
Existing connector assembly processes for electrical cables, particularly in the automotive and electromobility sectors, face challenges in achieving robust, safe connections that withstand high currents and voltages while being economically producible in high volumes, with a need for comprehensive documentation and automation.
Innovation Solution
A device comprising independent processing modules and a transport system for automated assembly of electrical connectors on cable ends, utilizing control units, grippers, and synchronized modules to facilitate efficient, high-volume production with quality assurance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fully automated connector assembly is implemented, then productivity and volume production capability are improved, but device complexity and documentation requirements increase
Solution Approach 1:
The device is divided into multiple independent processing modules (first processing module, second processing module, etc.), each capable of performing specific assembly operations. This segmentation allows the system to handle complex assembly tasks through coordinated simple modules, improving productivity while managing device complexity through modular architecture.
Solution Approach 2:
The processing modules are designed with universal functionality to handle different cable types and connector configurations. The modules can perform multiple operations (stripping, assembling, testing) and accommodate various cable diameters and connector types, enabling high-volume production of diverse products without requiring completely different assembly lines.
2Reliability
If comprehensive documentation of cable processing is implemented, then quality assurance and transparency are improved, but device complexity and process overhead increase
Solution Approach 1:
The device incorporates documentation systems that automatically record processing parameters, quality metrics, and assembly data from each processing module. This feedback mechanism ensures comprehensive quality assurance through automated data collection and tracking, reducing the need for manual documentation while maintaining high reliability standards.
3Adaptability or versatility
If multiple independent processing modules are used, then manufacturing flexibility and adaptability are improved, but device complexity increases
Solution Approach 1:
The processing modules are designed with adjustable and reconfigurable capabilities, allowing them to adapt to different cable types, diameters, and connector configurations. This dynamic adaptability enables a single modular device to handle multiple product variants, improving versatility while managing complexity through standardized interfaces and programmable controls.
Data Source
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AI summary
The invention relates to a device (131) for assembling an electrical plug connector (12) on a first cable end (3) and/or on a second cable end (4) of an electrical cable (1a, 1b) having one or more inner conductors (2). The device (131) has at least two independent processing modules (18, 19, 29, 35, 50, 59, 69, 93, 103, 109, 117, 134, 135, 137, 38, 139, 140, 141, 142, 143) for processing the cable (1a, 1b). The device (131) also has a common transport unit (71) for transporting the cable (1a, 1b) between at least two of the processing modules (18, 19, 29, 35, 50, 59, 69, 93, 103, 109, 117, 134, 135, 137, 38, 139, 140, 141, 142, 143) along a transport direction (T).