Modular Plug Connector Assembly for High-Precision Cable Ends
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Solution Overview
Problem
The assembly of electrical plug connectors on cable ends is complex and requires high precision, especially in the automotive industry where high-voltage cables demand robust and reliable connections, necessitating fully automated processes to ensure quality and efficiency.
Innovation Solution
A modular apparatus with processing modules and a control unit for automated assembly of plug connectors on cable ends, featuring a feed device, module transport device, and control units to manage processing steps, allowing for partial or complete assembly of plug connectors on both ends of electrical cables, particularly suitable for high-power transmission cables in electromobility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly processes are used for plug connectors, then flexibility and adaptability are maintained, but productivity is low and manufacturing precision is insufficient
Solution Approach 1:
The apparatus is divided into multiple independent processing modules, each performing a specific assembly operation (e.g., cable preparation, connector attachment, sealing). This modular structure enables automated high-speed assembly while maintaining system manageability and flexibility for different connector types.
Solution Approach 2:
The processing modules are designed with universal interfaces and adjustable parameters to handle various plug connector types and cable configurations. The control unit can program different assembly sequences and parameters for different product specifications, reducing the need for dedicated equipment for each connector type.
2Manufacturing precision
If complex assembly steps are performed manually, then adaptability to different connector types is maintained, but manufacturing precision and quality consistency deteriorate
Solution Approach 1:
The control unit receives feedback from sensors and processing modules to monitor assembly quality in real-time. This closed-loop control ensures that each assembly step meets precision requirements, with automatic adjustments or rejection of defective components, maintaining consistent quality across all produced connectors.
Solution Approach 2:
Manual mechanical assembly operations are replaced with automated processing modules that use precisely controlled mechanical, thermal, or chemical processes. This substitution eliminates human variability in assembly precision while the modular design keeps the overall system complexity manageable.
3Productivity
If automated processing modules are used, then productivity and manufacturing precision are improved, but device complexity increases
Solution Approach 1:
The control unit automatically manages the operation of processing modules based on programmed parameters and real-time feedback. The system self-regulates assembly sequences, adjusts processing parameters, and handles quality control without requiring complex manual intervention, simplifying operation despite the automated nature of the equipment.
4Reliability
If multiple processing modules are implemented, then assembly quality and robustness are improved, but loss of time in setup and configuration increases
Solution Approach 1:
The processing modules and control unit are pre-configured with standard assembly parameters and sequences for common connector types. This preliminary preparation allows for rapid setup when changing production runs, as the system can quickly load pre-programmed parameters rather than requiring extensive reconfiguration, thereby reducing setup time while maintaining robust assembly quality.
Data Source
AI summary
An apparatus for assembling an electrical plug connector on a first cable end and/or on a second cable end of an electrical cable which has one or more inner conductors. The apparatus has at least one module group with at least two processing modules for processing the cable. The apparatus furthermore has a feed device for feeding the cable end along a feed direction (X) to a processing station (B) in the module group. The module group has a module transport device for feeding in each case one of the processing modules of the module group to the processing station (B). The feed device is configured to remove the cable end from the module group counter to the feed direction (X) after the processing.