Platform to Fully Automate Coaxial Cable Assembly
The Automobile Industry’s high demand on performance, technical innovation and processing capabilities of HF/RF connectors that conform to FAKRA norms, has prompted connector manufacturers to continuously supply the market with increasingly innovative systems. Therefore, an array of different connector models are now available to consumers.
This poses many new challenges to machine designers as the need for automated economical solutions requires continuously increasing the performance of processing systems. Schleuniger’s answer to this challenge is the new TransferModule 6000.
FAKRA II Connector Models
The consistently rising customer demand for “on board” electronic data transmission options for automobiles, especially in areas such as car radio frequencies, multimedia, safety and security options and the use of high frequency Bluetooth, have prompted the connector manufacturers to continuously develop more powerful connector systems.
The FAKRA II plug standard was created to guarantee that plug connector systems from different manufacturers are compatible with one another (Common Cavity concept), as well as with the FAKRA I plug standard, and that they fulfill standard requirements at all times.
In reaction to the need to reduce costs, new connector system models have been designed to make a single piece crimp contact a central and inexpensive component. The processing of these types of contacts allows for unique and cost-effective solutions for fully automatic manufacturing processes.
FAKRA II Fully Automatic Connector Production
The TransferModule 6000 has been specially designed to provide a fully automatic assembly solution for multi part as well as one-piece connectors).
Coaxial cables can be automatically cut to the desired length and placed into the transfer chain’s transport cart. Then, depending on the desired output, a specific, multi-step machining process of the cable ends takes place. The following automated steps are currently available:
| • |
Multi step stripping of coaxial cables |
|
• |
Shunting of loose crimping sleeves |
|
• |
Trimming, enlarging or inversion of the shield netting |
|
• |
Crimping the inner conductor with Crimp Force Monitoring (CFM) or a three zone crimp for one part connector casings |
|
• |
Shunting of loose connector casings (plug / sockets) |
|
• |
Pushing back and crimping of crimp sleeves |
|
• |
Electrical testing of assembled cables |
|
• |
Defined cable storage |
|
• |
Flux/Tin Plating is optional, depending on customer needs |
Depending on the connector model and on the customer needs, different processing steps and an adapted machine concept are required. The multi-piece connector model, in which the loose connector pieces have to be fed and assembled, requires a more complex system and therefore, more capital intensive unit assembly. The single piece connector model is easier and cheaper to automate, as the feeding of loose parts is no longer required.
Schleuniger’s decades of coaxial cable experience make the TransferModule 6000 a versatile and cost effective option for the assembly of coaxial cables. The growing demand for communication, entertainment and security electronics in the automotive industry, combined with an immense cost and quality pressure opens up new challenges and opportunities for innovative machine builders as well as harness manufacturers.
For more information ask your local Schleuniger representative.
|