Terminal Carrier Guide Groove for Precise FPC Connector Insertion
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Solution Overview
Problem
Existing manual methods for inserting terminals onto Flexible Printed Circuits (FPC) or Flexible Flat Cables (FFC) into connectors are inefficient, inaccurate, and result in high scrap rates due to the need for manual alignment and control of insertion force and depth.
Innovation Solution
A terminal carrier with a fixture and a movable moving component featuring a guide groove that positions and guides terminals into a housing along a longitudinal direction, assisted by a driving device to automate the insertion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual insertion method is used, then device complexity is low, but productivity is low and manufacturing precision is poor
Solution Approach 1:
The insertion device is divided into distinct functional modules: a carrier for holding multiple terminals, a moving component for individual terminal extraction, and a guide groove for precise positioning. This segmentation allows automated high-speed insertion while maintaining manageable device complexity through modular design.
Solution Approach 2:
Terminals are pre-loaded onto the carrier in the correct arrangement before the insertion process begins. The moving component then sequentially extracts and inserts terminals one by one. This preliminary arrangement eliminates the need for real-time alignment during insertion, significantly improving productivity while keeping the device structure relatively simple.
2Manufacturing precision
If manual alignment is used, then device complexity is low, but manufacturing precision is poor
Solution Approach 1:
The guide groove acts as an intermediary positioning structure between the moving component and the terminal socket. It provides precise geometric constraints that automatically align the terminal during extraction and insertion, achieving high manufacturing precision without complex active positioning systems or sensors.
Solution Approach 2:
The terminal's own geometry interacts with the guide groove's shaped pathway to achieve self-alignment. The guide groove's contours are designed to match the terminal features, allowing the terminal to automatically position itself correctly as it is extracted and inserted, eliminating the need for external alignment mechanisms.
3Reliability
If manual insertion is used, then device complexity is low, but reliability is poor due to high scrap rate
Solution Approach 1:
The invention replaces manual tactile control with a mechanically constrained system. The guide groove provides fixed geometric pathways that ensure consistent insertion depth and angle, while the moving component uses controlled mechanical motion to extract and insert terminals. This eliminates human variability and improves reliability without requiring complex electronic control systems or sensors.
Data Source
AI summary
A terminal carrier comprises a fixture and a moving component. The fixture is adapted to clamp an electrical connection member connected to a terminal. The moving component is mounted on the fixture in a movable manner and can be moved relative to the fixture between an initial position and a final position along a longitudinal direction. A guide groove adapted to mate with the terminal is formed on the moving component, and positions and guides the terminal to be inserted into a housing along the longitudinal direction. When the moving component is in the initial position, the terminal is positioned in the guide groove. As the moving component is moved from the initial position to the final position, the terminal gradually extends from the guide groove to allow the terminal to be gradually inserted into the housing.