Ribbon Cable Crimping Jig for Stable Connector Alignment
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Solution Overview
Problem
Existing methods for installing ribbon cables on electrical connectors in industrial control and data network systems lack efficient alignment and retention solutions, leading to potential 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, allowing for precise positioning and crimping of the connector onto the cable, ensuring proper electrical termination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual alignment methods are used for ribbon cable installation, then the installation process is simple and requires minimal equipment, but the alignment precision is poor leading to electrical shorts and improper termination
Solution Approach 1:
The patent introduces a jig as an intermediary device between the manual alignment process and the final cable termination. The jig includes alignment features such as guide rails and positioning pins that physically guide the ribbon cable into proper alignment with the connector, thereby achieving precise alignment without requiring complex automated positioning systems.
Solution Approach 2:
The jig is designed to be self-aligning through its structural features. The cable track and connector retaining segment are configured with complementary geometries that automatically guide the cable and connector into correct relative positions during insertion, eliminating the need for external alignment tools or complex adjustment mechanisms.
2Stability of the object's composition
If no retention mechanism is used during crimping, then the device structure is simple, but the cable alignment stability is poor causing improper termination
Solution Approach 1:
The jig performs preliminary alignment and retention actions before the actual crimping operation. The cable is positioned and secured in the cable track, and the connector is retained in the retaining segment, ensuring proper alignment is established before the crimping force is applied. This preliminary positioning prevents misalignment during the crimping process.
Solution Approach 2:
The jig is divided into functional segments: a cable track segment for cable positioning, a connector retaining segment for connector holding, and a crimping interface segment. Each segment performs a specific function in the alignment and retention process, allowing the device to maintain cable stability through distributed mechanical constraints rather than a single complex mechanism.
3Reliability
If a reusable alignment device is implemented, then the termination reliability is improved, but the manufacturing cost increases
Solution Approach 1:
The jig is designed as a universal alignment device that can accommodate multiple types of connectors and cable configurations through adjustable or interchangeable components. The basic structure with cable track and connector retaining segment can be adapted to different connector types, allowing a single base design to serve multiple functions and reducing the need for specialized tools for each connector type.
Data Source
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.