Outer Conductor Contact Testing for Foreign Body Detection
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Solution Overview
Problem
Current methods for testing outer conductor contacts in coaxial cable assembly are inadequate as they often fail to detect foreign bodies like chips or fine hairs until the assembly is complete, leading to unnecessary scrap and potential short circuits.
Innovation Solution
A device and method for testing outer conductor contacts before assembly, utilizing a test pin that generates a predetermined electric field to detect electrically conductive foreign bodies, thereby identifying defective contacts and preventing their use in assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical testing is performed on fully assembled coaxial cables, then short circuits caused by foreign bodies can be detected, but defective cables are only identified at the end of assembly leading to increased scrap and loss of time
Solution Approach 1:
The test pin performs electrical testing on the outer conductor contact before the cable assembly is completed. By inserting the test pin into the outer conductor contact and applying a test voltage, foreign conductive bodies are detected in advance, allowing defective contacts to be identified and removed before they cause failures in the final assembled cable.
2Measurement precision
If optical inspection is used to examine outer conductor contacts, then visual defects can be detected, but foreign matter or short circuits cannot be reliably detected depending on location and appearance
Solution Approach 1:
The patent replaces optical inspection methods with an electrical testing method. Instead of using light and visual examination, a test pin applies electrical voltage to the outer conductor contact. Any conductive foreign body present will cause a measurable current flow or flashover, providing reliable detection regardless of the foreign body's visual characteristics or location within the contact.
3Reliability
If testing is performed after cable assembly, then comprehensive system testing is achieved, but defective outer conductor contacts cannot be individually identified and removed
Solution Approach 1:
The testing process is segmented to operate at the component level rather than only at the final assembly level. The test pin tests each outer conductor contact individually on the carrier strip before cables are assembled. This segmentation allows defective contacts to be identified and removed as individual components, preventing them from being incorporated into cable assemblies in the first place.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces rejects by identifying defective outer conductor contacts before assembly, saving time and resources, and preventing potential short circuits in assembled cables.
Implementation Method 1
a test pin (10) which can be at least partially inserted into the outer conductor contact (2) and generates a predetermined electric field so that electrically conductive foreign bodies located within the outer conductor contact (2) cause a short circuit
Data Source
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AI summary
The present invention relates to a device (1) for testing an external conductor contact (2) comprising a guide (6) with a feed mechanism for providing a carrier strip (4) with external conductor contacts (2) at a fixing area (7), a fixing device (8) for fixing an external conductor contact (2) to be tested at the fixing area (7), and a test pin (10) which can be at least partially inserted into the external conductor contact (2) and generates a predetermined electric field such that electrically conductive foreign bodies located within the external conductor contact (2) cause a short circuit. The invention further relates to a method for testing an external conductor contact (2).