Ribbon Cable Connector Assembly With Clamping Alignment Features
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Solution Overview
Problem
Existing connectors for ribbon cables in industrial control and data network systems lack universal components and efficient assembly mechanisms, leading to complexity and potential misalignment issues.
Innovation Solution
A connector design featuring a housing, cable organizer, and cover with nonplanar surfaces for tool engagement, along with mechanical indicators for proper assembly, allowing for universal components and secure alignment of ribbon cables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional connector assembly methods are used, then assembly complexity increases and alignment precision deteriorates, but manual assembly processes are simpler in terms of tooling requirements
Solution Approach 1:
A clamping tool is introduced as an intermediary device to achieve precise alignment and secure assembly of the connector components. The tool features a pivoting plate with a contact surface that interfaces with the nonplanar surface of the cover, enabling controlled application of clamping force to ensure proper alignment between the housing, cable organizer, and cover during assembly
Solution Approach 2:
The cover is designed with a pre-formed nonplanar surface including an inverted bump, and the clamping tool is designed with a corresponding pivoting plate contact surface, so that when the tool is applied, the clamping force is automatically directed to the correct location to achieve proper alignment and secure connection without requiring additional adjustment steps
2Adaptability or versatility
If universal components are implemented, then adaptability improves and manufacturing efficiency increases, but design complexity may increase to ensure compatibility
Solution Approach 1:
The connector is designed with universal components including a standardized housing, cable organizer, and cover assembly that can be used across different connector types. The cover with its nonplanar surface and the clamping tool with the pivoting plate form a universal assembly mechanism that can accommodate various ribbon cable connectors, improving manufacturing efficiency and component interchangeability while maintaining controlled design complexity through standardization
3Reliability
If nonplanar surfaces for tool engagement are added, then assembly security improves and alignment precision increases, but manufacturing complexity increases
Solution Approach 1:
The cover is designed with a nonplanar surface featuring an inverted bump (a curved geometric feature) that provides a precise engagement point for the clamping tool's pivoting plate. This curved feature ensures secure tool engagement and proper force application during assembly, improving assembly security and alignment precision. The geometric feature is integrated into the cover molding process, which minimizes the increase in manufacturing complexity while achieving the desired assembly reliability
Data Source
Figure 1~1A
Figure 2
Figure 3
AI summary
A connector for receiving a ribbon cable, to be assembled via a clamping tool, is provided. The connector includes a housing, a cover, and a protection cap. The housing includes an open top and a bottom. The cover is configured to selectively cover the open top of the housing to enclose the ribbon cable within an interior of the housing. The protection cap is configured to cover the bottom of the housing. The protection cap includes a nonplanar surface with a bump, where the clamping tool contacts the cover and the bump to force the cover toward the housing when the connector is assembled.