Automated Plug Fabrication with 90° Contact Bending
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Solution Overview
Problem
The production of plugs with 90° inclined contacts is complex and time-consuming, and automation of this process has not been possible with reliable and reproducible results due to the small size of the contacts and housing, making it difficult to achieve cost-effective and accurate fabrication.
Innovation Solution
A method involving a plug fabrication device with holding arrangements for the plug housing and contact pivoting to bend elongate contacts from straight to 90° within the housing, allowing for automated and efficient production of plugs directly on a prepared cable with crimp contacts already attached to the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimp contacts are inserted from behind into a plug housing and bent using a bending tool through an access opening, then the crimp contact is fixed inside the housing, but the process is complex and does not achieve 90° inclined contacts
Solution Approach 1:
Instead of inserting bent contacts from behind and bending them transversely, the invention inserts straight contacts from the front and bends them in-place within the housing. This inversion of the insertion and bending sequence simplifies the process while achieving the desired 90° inclination.
Solution Approach 2:
The invention uses a bending element that acts as an intermediary tool to bend the contacts from the front. This bending element can be introduced through the front opening of the housing and performs the bending operation without requiring complex access from behind the housing.
2Manufacturing precision
If contacts are slid from one side into the housing and bent from the other side, then the contact is bent, but automation is difficult due to the complex sliding and bending sequence
Solution Approach 1:
The invention inverts the process by inserting contacts from the front and bending them in-place, rather than sliding from one side and bending from the other. This inversion enables automation because the bending operation can be performed by a bending element accessible from the front, where automated tools can easily reach and manipulate the contacts.
3Ease of manufacture
If crimp contacts are placed in the housing before crimping, then the crimping process can be performed, but the process is complex and time-consuming
Solution Approach 1:
The invention performs the bending operation as a preliminary action before final assembly and testing. By bending the contacts in-place within the housing during the insertion process, the need for subsequent complex bending operations is eliminated, streamlining the manufacturing flow and improving productivity.
4Manufacturing precision
If pre-bent contacts are crimped onto cable cores and then introduced into the plug housing, then the contacts are pre-formed, but the process is very complex and requires enormous outlay for automation
Solution Approach 1:
The invention performs the bending operation as a preliminary action during the insertion process itself, before final assembly. By bending the contacts in-place within the housing using a front-accessible bending element, the need for pre-bending equipment and complex automated handling of pre-bent contacts is eliminated, significantly reducing automation complexity and equipment outlay.
Data Source
AI summary
The invention relates to a method for fabricating a plug (18) formed from a plug housing (19) and elongate contacts (3), the contacts (3) comprising a bent longitudinal axis (23) inside the finished plug (18), characterized by:introducing front portions (3a) of the contacts (3) into contact receptacles (17) of a plug housing part (7);holding the plug housing part (7) by means of a first holding arrangement (15) of a plug fabrication device (20);holding rear portions (3b) of the contacts (3) by means of a second holding arrangement (21) of the plug fabrication device (20);pivoting the first holding arrangement (15) with the plug housing part (7) held thereby relative to the second holding arrangement (21) with the contacts (3) held thereby, whereby the longitudinal axis (23) of the contacts (3) is bent in the region between their front portions (3a) and their rear portions (3b).