Riveted Cable Connector Assembly Reducing Labor Intensity
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Solution Overview
Problem
The existing cable connector assembly process is labor intensive due to the use of welding methods, which is inefficient and prone to errors, especially when dealing with small intervals between terminals and wires.
Innovation Solution
A cable connector design that incorporates riveting zones on terminals and wires, allowing for assembly using a riveting method instead of welding, with adjustable intervals and a locking mechanism to secure the second body onto the first body, reducing assembly time and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If welding method is used to connect terminals and wires, then reliable electrical connection is achieved, but assembly process becomes labor intensive and inefficient
Solution Approach 1:
The patent replaces the welding method (thermal/mechanical process) with a riveting method (mechanical fastening process). The riveting zone on terminals and corresponding structures on wires enable mechanical connection instead of welding, significantly reducing assembly complexity and labor intensity while maintaining connection reliability.
Solution Approach 2:
The patent incorporates riveting zones that are pre-formed on terminals and corresponding structures pre-formed on wires before assembly. This preliminary preparation of connection features enables rapid riveting assembly without complex positioning or alignment procedures during the assembly process, thereby improving productivity.
2Volume of moving object
If small intervals between terminals and wires are used, then compact connector design is achieved, but welding becomes more difficult and error-prone
Solution Approach 1:
By replacing welding with riveting, the patent enables compact designs with small intervals between terminals and wires. The riveting method does not require the clearance and access that welding processes need, allowing for tighter spacing and more compact connector overall dimensions while reducing assembly difficulty.
Solution Approach 2:
The patent divides the connection interface into distinct riveting zones on terminals and corresponding structured regions on wires. This segmentation allows for precise localization of connection points, enabling compact arrangements while maintaining ease of assembly through the standardized riveting process.
3Productivity
If riveting method is used to connect terminals and wires, then assembly process is simplified and efficiency improved, but connection reliability must be maintained
Solution Approach 1:
The patent replaces welding with riveting, maintaining connection reliability through mechanical interlocking. The riveting zone design on terminals and corresponding structures on wires create a robust mechanical connection that ensures reliable electrical connectivity while enabling simpler and more efficient assembly processes.
Solution Approach 2:
The patent employs curved or bent terminal configurations (bending line shaped or curving line shaped) that follow the spatial arrangement of wires. This curving design ensures optimal contact and mechanical interlocking in the riveting process, maintaining connection reliability while accommodating compact layouts and simplifying assembly.
Data Source
AI summary
A cable connector with a first body, a plurality of terminals, and a plurality of wires is provided. The first body comprises a plurality of first slots and a plurality of second slots. The terminals comprise a plurality of first terminals and a plurality of second terminals. Each of the first terminals and the second terminals comprises a contacting zone, a fixing zone, and a riveting zone. The first terminals and the second terminals are respectively in the first slots and the second slots of the first body. Each of the wires having a connecting part corresponding to one of the riveting zones of the first terminals and the second terminals, and a part of some of the wires are covered by insulating layers. The connecting parts of the wires are connected with the riveting zones of the corresponding terminals.