Socket Contact Assembly Using Parallel Sleeve and Cage Forming
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Solution Overview
Problem
Existing methods for producing socket contacts require separate manufacturing and assembly of components, leading to inefficiencies such as stock maintenance, alignment issues, and varying production speeds, resulting in costly and time-consuming processes.
Innovation Solution
A method where a sleeve and contact cage are formed from metal strips using parallel shaping processes, with perforation and punching to create interconnected blanks that are then separated and formed into tubular shapes, allowing for direct assembly without additional alignment and maintaining consistent production speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate manufacturing processes are used for sleeve and contact cage, then each component can be manufactured independently, but production time increases and productivity decreases due to sequential processing
Solution Approach 1:
The patent combines the manufacturing of sleeve and contact cage into a single parallel forming process using one stamping device with multiple punching units. Both components are formed simultaneously from separate metal strips fed through the same device, eliminating sequential processing and increasing productivity while maintaining independent component manufacturing capabilities.
2Adaptability or versatility
If separate manufacturing processes are used for sleeve and contact cage, then manufacturing flexibility is maintained, but additional feeding processes and warehousing are required
Solution Approach 1:
The patent merges the feeding systems for sleeve and contact cage into a single stamping device with multiple feeding mechanisms. Both metal strips are fed simultaneously through the same device, eliminating separate feeding processes and warehousing requirements while maintaining the ability to manufacture different components independently.
Solution Approach 2:
The patent implements preliminary feeding and positioning of metal strips within the stamping device before the forming process begins. This preliminary action ensures that both components are ready for simultaneous manufacturing, eliminating the need for separate warehousing and feeding processes during production.
3Manufacturing precision
If manufacturing processes are synchronized, then production consistency is achieved, but production speed decreases due to throttling
Solution Approach 1:
The patent employs dynamic control of multiple punching units operating in parallel within the same stamping device. Each unit can operate at optimized speeds for its specific component while the overall system maintains synchronization through coordinated control, achieving both production consistency and high productivity without throttling.
Data Source
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AI summary
The invention relates to a method for producing a socket contact consisting of a sleeve and a contact cage which are formed from a first and a second metal strip. In said method, at least one step for forming the sleeve and a step for forming the contact cage are carried out in a parallel shaping process.