Ribbon Cable Alignment Jig for Accurate Connector Crimping
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for installing ribbon cables on electrical connectors are inefficient, lacking proper alignment and registration, which can lead to electrical shorts and improper termination.
Innovation Solution
A reusable jig device with a side portion and central piece is used to align and retain the ribbon cable, featuring a cable track and connector retaining segment to ensure precise positioning and crimping of the connector onto the cable, utilizing a clamping tool to apply compressive forces for secure installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment methods are used for ribbon cable installation, then the installation process is simple, but alignment precision and registration accuracy deteriorate leading to electrical shorts and improper termination
Solution Approach 1:
The patent introduces a positioning fixture as an intermediary device between the ribbon cable and electrical connector. The fixture includes alignment guides and registration features that mechanically ensure precise positioning during installation, eliminating the need for complex manual alignment procedures while maintaining high precision.
Solution Approach 2:
The positioning fixture is pre-configured with alignment features and registration elements before the installation process begins. The ribbon cable and connector are designed with complementary positioning features that automatically align when the connector is inserted into the fixture, performing the alignment action in advance rather than during the crimping operation.
2Manufacturing precision
If proper alignment devices are implemented, then registration accuracy improves, but the complexity of the installation system increases
Solution Approach 1:
The positioning fixture employs self-aligning features where the geometry of the fixture, cable, and connector work together automatically. The alignment guides and registration elements are designed so that proper positioning occurs naturally through the mechanical interaction of the components themselves, without requiring additional active alignment mechanisms or complex control systems.
3Manufacturing precision
If precise positioning mechanisms are used, then installation quality improves, but installation time and process complexity increase
Solution Approach 1:
The positioning fixture is pre-configured with alignment features and registration elements before the installation process begins. The ribbon cable and connector are designed with complementary positioning features that automatically align when the connector is inserted into the fixture, performing the alignment action in advance rather than during the crimping operation.
Data Source
Figure 1A
Figure 2
Figure 3~4
AI summary
A device is provided for aligning a ribbon cable relative to an electrical connector to crimp the electrical connector onto the ribbon cable with a tool. The device includes a side portion and a central piece. The side portion includes an upper end and a cable track having a width sized to receive the ribbon cable. The central piece is coupled to the side portion and includes an upper surface. The upper surface of the central piece and the upper end of the side portion at least partially define a connector retaining segment sized to receive the electrical connector.