Staged Ram Crimp Head for PCB Connector Termination
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Solution Overview
Problem
Existing methods for terminating a wire to a printed circuit board (PCB) using a connector assembly are inefficient and can damage the solder joint between the connector and the PCB, leading to impaired electrical connections and increased production costs.
Innovation Solution
A tool for a connector assembly featuring a crimp head with a ram assembly that includes a connector ram and a shield ram, which moves in stages to terminate the wire by pressing the cap and shield of the connector against the PCB, avoiding direct force transfer to the PCB.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cover is pressed manually or with existing tools to terminate the wire, then the wire can be connected to the connector, but the insertion force is dispersed to the PCB causing damage to the solder joint and impairing electrical connection
Solution Approach 1:
The tool introduces a intermediary mechanism (ram assembly with connector ram and shield ram) between the driving force and the connector cover. This intermediary structure controls and directs the insertion force through the cover to the connector components, preventing direct force transfer to the PCB and protecting the solder joint while maintaining reliable electrical connection
Solution Approach 2:
The ram assembly is segmented into multiple components (connector ram and shield ram) that move in stages. This segmentation allows the insertion force to be applied progressively through different stages, with each stage handling specific portions of the termination process, thereby controlling force distribution and preventing damage to the solder joint
2Productivity
If existing tools are used to terminate the wire in the connector, then the termination can be completed, but the process is inefficient and increases production costs
Solution Approach 1:
The tool merges multiple functions into a single integrated device: the crimp head houses both the connector ram and shield ram, and the driving portion provides unified actuation for both rams. This combined structure performs both the connector termination and shield termination in one operation, improving productivity and reducing production costs by eliminating the need for separate tools or operations
Data Source
AI summary
A tool for a connector assembly includes a crimp head having a tool housing and a ram assembly disposed within the tool housing, the ram assembly has a connector ram and a shield ram disposed within the connector ram. The tool includes a driving portion driving movement of the ram assembly with respect to the tool housing from a retracted position to a terminated position along a longitudinal direction. The connector ram and the shield ram are movable together with respect to the tool housing from the retracted position to an intermediate position between the retracted position and the terminated position. The shield ram is movable with respect to the connector ram from the intermediate position to the terminated position of the ram assembly.