Radial Jack Sheet Metal Sleeve Assembly
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Solution Overview
Problem
Existing methods for producing electrical connector sockets are complex and costly due to the need for precise geometric matching of sleeves, end sleeves, and laminar cages, leading to high production expenses and inefficiencies, particularly with the use of dovetail joints and complex material-locking joining methods.
Innovation Solution
A method involving a cylindrical socket sleeve formed from a flat sheet metal part with retaining arms and latching lugs, where the sheet metal is rolled to create a cylindrical shape with the arms engaging in recesses, simplifying the assembly process and reducing the number of components, allowing for a more economical and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional dovetail joints and complex material-locking joining methods are used to assemble sleeves and laminar cages, then the geometric matching and fitment precision are improved, but the production complexity and cost increase significantly
Solution Approach 1:
The sleeve is segmented into a body portion and separate holding arms with latching lugs, allowing independent formation and assembly. The contact grid is segmented into multiple contact lamellae within a cage structure. This segmentation enables simpler individual components to be assembled through straightforward engagement of latching lugs with recesses, avoiding complex dovetail joint geometry while maintaining precise fitment.
Solution Approach 2:
The holding arms are pre-formed with latching lugs positioned to engage with recesses in the contact grid cage during assembly. The sleeve body is pre-formed with the necessary geometry to receive and secure these holding arms. This preliminary preparation of joining features eliminates the need for complex real-time joining operations during assembly, reducing both complexity and cost while ensuring precise geometric matching.
2Manufacturing precision
If high-precision tubes are used for the sleeve to ensure proper fitment of the laminar cage, then the manufacturing precision is improved, but the production cost increases due to expensive turning operations
Solution Approach 1:
The sleeve is formed from sheet metal through rolling and bending operations that create the necessary cylindrical geometry and tolerances without requiring expensive precision tube turning. The dimensional parameters are controlled through forming process parameters rather than post-processing machining, significantly reducing manufacturing cost while achieving the required fitment precision for the contact grid cage.
Solution Approach 2:
The sleeve is manufactured as a cost-effective sheet metal formed component rather than an expensive precision-turned tube. The design accepts the tolerances achievable through forming operations, eliminating the need for high-precision machining. This approach treats the sleeve as an economical disposable component that achieves sufficient precision through intelligent design rather than expensive manufacturing processes.
3Stability of the object's composition
If the contact grid is firmly clamped at both ends in the sleeve, then the mechanical stability is improved, but the contact system becomes mechanically overdetermined and experiences increased stresses during plugging and operation
Solution Approach 1:
The holding arms are designed with elastic properties that allow them to flex and adapt during assembly and operation. Rather than rigid clamping, the holding arms provide a dynamic, compliant connection that accommodates thermal expansion, vibration, and plugging forces without creating excessive stress concentrations. This dynamic approach maintains mechanical stability while reducing stress on the contact grid.
4Manufacturing precision
If multiple joining operations and tools are used to assemble the connector socket components, then the assembly precision is improved, but the production speed decreases
Solution Approach 1:
Multiple joining functions are merged into single integrated features. The holding arms simultaneously provide structural support, positioning, and joining functions through their latching lug engagement with recesses. The sleeve body integrates the contact grid mounting features directly into its structure. This merging of functions reduces the number of separate operations and tools required, increasing production speed while maintaining assembly precision.
Solution Approach 2:
The latching lugs on the holding arms and recesses in the contact grid cage are designed to self-align and self-engage during assembly. The geometry of these features guides the components into proper alignment and secures them without requiring complex tooling or multiple adjustment operations. This self-service assembly mechanism maintains precision while dramatically increasing production speed.
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
This approach simplifies the production process, reduces component complexity, and increases production speed while maintaining precise fitment, addressing the issues of tolerance and cost associated with traditional methods.
Implementation Method 1
The sheet metal part is rolled to form a cylindrical socket sleeve
Implementation Method 2
two retaining arms protruding from one transverse side edge of the sheet metal part, in each case in extension of two longitudinal side edges, with the retaining arms having a latching lug on a respective free end of the retaining arm for engaging in an undercut, which in each case is designed as a corresponding recess in the other end section
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention relates to a method for manufacturing an electric connector jack comprising a cylindrical jack sleeve which includes a receiving space into which a cylindrical contact lamination grating is inserted that has a plurality of parallel contact laminations.