Multi-Wire Cable Connector with Guided Wire Alignment
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Solution Overview
Problem
The existing methods for connecting multi-wire electrical cables are time-consuming and prone to errors, requiring manual stripping and securement of each wire, with no efficient solution for reconnection if initial connections are poor.
Innovation Solution
A connection device with guide paths and a retaining portion that systematically positions wires, allowing a complementary module to connect them with a single translation movement, using insulation-displacement connectors for secure and error-free connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual wire stripping and connection is used, then connection reliability can be achieved, but installation time and complexity increase significantly
Solution Approach 1:
The connection device performs preliminary actions by automatically positioning and pre-connecting multiple wires to their respective terminals before the final cable assembly is installed. The guide paths pre-align the wires, and the connection portions establish initial connections, so that when the cable is inserted, the connections are already in place, eliminating the need for manual wire-by-wire connection during installation.
Solution Approach 2:
The connection device enables self-service connection where the cable and wires themselves perform the connection action. As the cable is inserted into the passage, the wires are automatically guided into their respective connection portions and make contact with the terminals through the single insertion movement, without requiring manual manipulation or separate connection steps.
2Manufacturing precision
If manual wire connection is performed, then connection accuracy can be controlled, but the process becomes complex and error-prone
Solution Approach 1:
The connection device is segmented into distinct functional portions: a passage for cable insertion, guide paths for each wire, and connection portions for terminal contact. Each wire has its own dedicated guide path and connection portion, which are arranged in specific spatial configurations. This segmentation ensures that each wire is independently guided and connected to the correct terminal, preventing connection errors while simplifying the overall process.
Solution Approach 2:
The guide paths act as intermediaries between the cable entry and the terminal connections. These guide paths physically guide and constrain the wires along predetermined trajectories, ensuring that each wire reaches its intended connection point accurately. The guide paths mediate the transition from cable insertion to precise wire-to-terminal alignment, eliminating the need for manual positioning.
3Ease of repair
If traditional connection methods are used, then reconnection is possible, but it requires complete disassembly and manual re-stripping
Solution Approach 1:
The connection device incorporates dynamic elements that allow for easy disassembly and reassembly. The retaining portion can be moved between a retained position (holding the cable securely) and a released position (allowing cable removal). This dynamic mechanism enables quick reconnection by simply moving the retaining portion to the released position, removing the cable, and reinserting it, without requiring manual wire stripping or complex disassembly procedures.
Data Source
AI summary
A connection device, for connecting a multi-wire electrical cable to a complementary module. The connection device includes a main portion, which forms a guide passage for one end of the cable, and a holding portion, which is fixed to the main portion. The holding portion includes guide paths, each of which is configured to receive a respective wire of the cable, so as to hold the corresponding wire in a predetermined position relative to the holding portion, where the wires are accessible along a connection direction. The connection device is configured to cooperate with the complementary module by bringing the complementary module closer to the connection device in a connecting movement parallel to the connecting direction, so as to connect the complementary module to the wires received in the guide paths.