Ribbon Cable Crimping Jig for Precise Connector Registration
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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 registration, leading to potential electrical shorts and suboptimal termination.
Innovation Solution
A reusable, one-piece jig is used to align and retain a ribbon cable relative to a connector during installation, ensuring proper registration and minimizing the risk of electrical shorts by using a cable guide segment and connector retaining segment to facilitate crimping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional installation methods are used without alignment devices, then the installation process is simpler and faster, but alignment precision deteriorates leading to electrical shorts and suboptimal termination
Solution Approach 1:
The patent introduces a jig as an intermediary alignment device that mediates between the installer and the connector-cable assembly. The jig provides reference surfaces and positioning features that ensure precise alignment during installation, eliminating the need for complex manual alignment procedures while maintaining high precision.
Solution Approach 2:
The jig is designed to pre-position the cable and connector components in the correct alignment before the actual installation occurs. By performing alignment preliminarily through the jig's structured geometry, the patent eliminates the need for complex real-time alignment adjustments during installation.
2Manufacturing precision
If manual alignment methods are used, then the installation process is faster and less complex, but registration accuracy deteriorates causing potential electrical shorts
Solution Approach 1:
The jig acts as a mediator that pre-establishes accurate registration between cable conductors and connector contacts. By using the jig's precision-machined reference surfaces, installers achieve accurate registration quickly without time-consuming manual alignment procedures.
Solution Approach 2:
The jig performs the time-consuming alignment and registration preparation in advance, allowing the actual installation to proceed rapidly. The pre-positioned components in the jig ensure that when the installer proceeds with crimping, accurate registration is already established.
3Reliability
If proper alignment devices are used, then electrical termination reliability is improved, but device complexity and initial setup time increase
Solution Approach 1:
The jig serves as a reliable intermediary that ensures consistent, repeatable alignment and registration for every installation. This mediator provides mechanical constraints and reference surfaces that guarantee proper positioning, significantly improving termination reliability while maintaining relatively simple device geometry.
Solution Approach 2:
The jig performs preliminary alignment and positioning actions that ensure reliable termination. By pre-establishing the correct geometric relationships between components, the jig eliminates variability in manual alignment and ensures consistent, reliable results for each installation.
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.