TECHNICAL FIELD OF INVENTION
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The present invention relates to a plug device for plugging a plurality of small elongated parts into a plurality of holes arranged in a part carrier.
BACKGROUND OF INVENTION
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While the production of electrical cable harnesses for vehicles a plurality of different variants has to be considered. The electrical cable harnesses are adapted to the requirements of the vehicles. A vehicle that's high equipped with various support devices needs a different electrical cable harness than a low equipped vehicle. That leads to the need of a variety of cable harnesses. To keep the cost for the variants as low as possible, the cable harness makers use standard module to build the electrical harnesses. For example a connector housing is used for a variety of cable harness variants. The connector housing is usually oversized for low equipped vehicles. The electrical cable harness for this vehicle may comprise les electrical cables. That guide to the fact that not all cavities in the connector housings carry contact parts in it. To prevent empty cavities usually small elongated parts of plastics are plugged in the housing cavities. The assemble step of plugging the small elongated parts of plastics into the empty housing cavities is done usually manually by a worker. The worker grabs one of the small elongated parts from the desk where they are provided as loose fill and plug it into the connector cavity. Because the small elongated parts are small they are often difficult to grabs and the worker has to try several times. That takes time and increases costs.
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Therefore one aspect of the present invention is to improve the state of the art by providing a device that makes it easier to grasp on of the small elongated parts. Furthermore the device has to be robust and easy to operate.
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These and other objects which become apparent upon reading the following description are solved by a plug device according to independent claim 1 and a method for providing a plurality of small elongated parts aligned to a worker according claim 15.
SUMMARY OF THE INVENTION
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The present application relates to a plug device for plugin a plurality of small elongated parts into a plurality of holes arranged in a part carrier. The plug device comprises a body comprising a main member and a wall. The wall extends from the main member along a first axis, thereby surrounding the first axis defining a cylindrical cup. The main member comprises an outer opening on an outer surface of the cylindrical cup and a plurality of inner openings on an inner surface of the cylindrical cup. The outer opening and the plurality of inner openings are connected by at least one channel. The channel is adapted to guide pressurized gas into the cylindrical cup. An open portion of the cylindrical cup comprises fastening means that cooperate with fastening means arranged on the part carrier to close the open portion by fastening the part carrier to the cylindrical cup. When the part carrier is fastened, the plurality of holes are adjusted along the first axis. The plurality of holes are adapted to let out pressured gas out of the cylindrical cup.
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The disclosed invention uses pressurized gas to create a gas turbulence while it is pressed through the closed body of the plug device. The pressurized gas is pressed into the outer opening. A channel that is connected to the outer opening provide a path for the pressurized gas to the inner openings. The pressurized gas leaves the inner opening as a gas stream. The gas streams have a direction and an energy depending on the gas pressure as well as the geometry of the openings and the channel. Furthermore the geometry of the inner space of the device is important. The gas streams are in communication with each other and also with the inner surface of the device. This communication creates gas turbulences. Each of the plurality of the small elongated parts has a small mass so that the small elongated parts are light enough to be whirled up by the gas turbulences. The pressurized gas leaves the plug device through the plurality of holes in the part carrier. If the parameters, comprising the geometries and gas pressure (above mentioned) and the shape and weight of the small elongated parts are well balanced, at least a plurality of the small elongated parts is plugged in the holes of the part carrier. When a swirling small piece is aligned along the first axis and at the same moment the tip of the small piece comes close to the opening, the escaping gas pulls it into the hole. The small piece is than plugged in the hole whereby the gas pressure inside the device holds it in position. Usually the small piece has one end that fits into the hole and the other not. Otherwise the small piece could be pressed through the hole to outside. In production plants the pressurized gas is usual pressurized air provided by the standard pressurized air support devices. The inventive plug device works with air pressures in the range of 5 to 10 bar. This makes it possible to operate the plug device with standard pressurized air support devices.
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Preferably the wall extends rotationally symmetrical around the first axis. This generates a rotationally symmetrical interior space. That makes it easier to control the pressured gas.
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According to a preferred embodiment the outer opening is centered by the first axis. From the centered opening the pressured gas can spread out evenly to the inner openings. That also enables an easy design.
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Preferably the plurality of inner openings are distributed evenly over the inner surface. This distribution provides even gas streams into the interior of the plugging device. The distribution of the openings can be varied in a wide range to adapt the plug device to the geometry of the small elongated parts. It also could be possible that an unevenly distribution of the openings may provide an acceptable plug result.
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Advantageously, the plurality of inner openings are evenly distributed along concentric circles surrounding the first axis. This provides controlled gas stream arrangements.
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Preferably three concentric circles are distributed evenly, perpendicular to the first axis, centered on the first axis. This provides controlled gas stream arrangements.
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Advantageously, the wherein four inner openings are distributed evenly along each concentric circle. This provides controlled gas stream arrangements.
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Preferably the position of the inner openings, arranged on the concentric circle closest to the wall, are rotated by 45° around the first axis in relation to the inner openings that are more far away the wall. This provides controlled gas stream arrangements.
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Preferably the inner openings have a round cross-section. A round cross section is easy to manufacture and provides an even valve effect.
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In a preferred embodiment, the diameter of the inner openings, arranged on the concentric circle closest to the wall, is half the diameter of the inner openings that are more far away the wall. This geometry provides a kind of gas turbulences inside the plug device that provide a high plug in ratio.
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Advantageously, the at least one channel has a bigger cross-section, than each of the inner opening. The bigger channel cross-section grants for that the gas pressure inside the device stays on a certain level.
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Advantageously, the wherein the cross section of the holes in the part carrier, are smaller than the cross section of the inner openings. The smaller holes grants for that the gas pressure inside the device stays on a certain level.
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Preferably the small elongated parts comprises a first end portion that has a bigger cross section than a second end portion.
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Preferably the cross section of the holes is bigger than the cross section of the second end portion of the small elongated parts and wherein the cross section of the holes is smaller than the cross section of the first end portion of the small elongated parts. Each small piece has one end that fits into the hole and the other not. Otherwise the small piece could be pressed through the hole to outside.
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The invention also comprises a method for providing a plurality of small elongated parts to a worker by using a plug device according to any preceding claim comprising the steps:
- a) Providing plug device for plugin a plurality of small elongated parts into a plurality of holes arranged in a part carrier, the plug device comprises a body comprising a main member and a wall, the wall extends from the main member along a first axis, thereby surrounding the first axis defining a cylindrical cup, wherein the main member comprises an outer opening on an outer surface of the cylindrical cup and a plurality of inner openings on an inner surface of the cylindrical cup, wherein the outer opening and the plurality of inner openings are connected by at least one channel, whereby the channel is adapted to guide pressurized gas into the cylindrical cup, wherein an open portion of the cylindrical cup comprises fastening means that cooperate with fastening means arranged on the part carrier to close the open portion by fastening the part carrier to the cylindrical cup, wherein when the part carrier is fastened, the plurality of holes are adjusted along the first axis and wherein the plurality of holes are adapted to let out pressured gas out of the cylindrical cup ;
- b) Fill in a number small elongated parts dependent on the number holes of small elongated parts in the cylindrical cup of the plug device. Dependent on the number of holes the best number of small elongated parts has to be find out. A considerable amount are 30-100 small elongated parts;
- c) Mount the part carrier on the cylindrical cup;
- d) Adjust the first axis perpendicular to Earth surface whereby the a part carrier is the bottom part;
- e) Apply pressured gas to the outer opening. The pressurized gas is pressurized air having 5 to 10 bar;
- f) Wait some seconds. The average time its 20 seconds.
- g) Remove the pressured gas;
- h) Dismount the part carrier from the cylindrical cup
- i) Provide the plurality of small elongated parts arranged along the first axis, partly plugged in the plurality the holes.
Description of the preferred embodiments
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In the following, the invention is described exemplarily with reference to the enclosed figures, in which
- Fig. 1
- shows a perspective, view of the plug device;
- Fig. 2
- shows another perspective, view of the plug device;
- Fig. 3
- shows a view to inside the cylindrical cup from the open portion;
- Fig. 4
- shows a cut, view of the cylindrical cup shown in Fig. 3
- Fig. 5
- shows a plan view to the inner surface of the part carrier;
- Fig. 6
- shows a plan view to the outer surface of the part carrier;
- Fig. 7
- shows a perspective, view to the inner surface of the part carrier with a plurality of unplugged and plugged small elongated parts;
- Fig. 8
- shows a perspective, more detailed view to the small elongated parts;
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Figure 1 shows a perspective, view of a plug device 1 for plugin a plurality of small elongated parts 200 into a plurality of holes 120 arranged in a part carrier 100. The plug device 1 comprises a body comprising a main member 30 and a wall 20a, 20b. In this embodiment the wall 20a, 20b is defined by two parts. The advantage of this design is that the fill in of the small elongated parts can be done while one wall part 20b is connected to the part carrier 100. The small elongated parts 200 can be filled in like in to a cup. The wall 20a, 20b extends from the main member 30 along a first axis X, thereby surrounding the first axis X defining a cylindrical cup 70. The wall 20a, 20b extends rotationally symmetrical around the first axis X. The main member 30 comprises an outer opening 32 on an outer surface 72 of the cylindrical cup 70. The outer opening 32 is centered by the first axis X. An open portion 76 of the cylindrical cup 70 comprises fastening means that cooperate with fastening means arranged on the part carrier 100 to close the open portion 76 by fastening the part carrier 100 to the cylindrical cup 70. The fastening is done in this embodiment by the sleeve shaped open portion 76 in communication with a rib 102 on the part carrier 100. The rib 102 surrounds the plurality of holes 120 of the part carrier 100. The rib 102 is in contact with the inner surface of the open portion 76 when fastened. The rib 102 is pressed against the inner surface of the open portion 76 to keep the pressured gas inside the plug device 1. The open portion and the rib 102 can also be screwed into each other. If necessary a seal can be foreseen between the two parts. After the part carrier 100 is fastened, the plurality of holes 120 are adjusted along the first axis X. The plurality of holes 120 are adapted to let out pressured gas out of the cylindrical cup 70. The part carrier 100 has a thickness along the first axis X. The holes 120 extend to bores that are adjusted along the first axis X. The diameter of the bores can decrease from the inner surface 140 to an outer surface 150 of the part carrier 100.
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Figure 2 shows another perspective, view of the plug device 1. A plurality of inner openings 40-47, 50-53 are arranged on an inner surface 74 of the cylindrical cup 70. A frame 130 is attached on the part carrier 100 that prevent an accidentally clog of the holes 120 from outside. The frame 130 is also usable as a stand for the plug device 1 thereby grants free gas flow out of the plug device 1.
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Figure 3 shows a view to inside the cylindrical cup 70 from the open portion 76. The outer opening 32 and the plurality of inner openings 40-47, 50-53 are connected by at least one channel 60. The channel 60 is adapted to guide pressurized gas into the cylindrical cup 70. In this embodiment the channel 60 is shaped like a cross with four arms spreading out from the outer opening 32 and connecting a tubular channel part surrounding the first axis. The plurality of inner openings 40-47, 50-53 are distributed evenly over the inner surface 74. The plurality of inner openings 40-47, 50-53 are evenly distributed along concentric circles surrounding the first axis X. Three concentric circles are distributed evenly, perpendicular to the first axis X, centered on the first axis X. Four of the inner openings 40-47, 50-53 are distributed evenly along each concentric circle. The position of the inner openings 50-53, arranged on the concentric circle closest to the wall 20, are rotated by 45° around the first axis X in relation to the inner openings 40-47 that are more far away the wall 20. The inner openings 40-47, 50-53 have a round cross-section. The diameter of the inner openings 50-53, arranged on the concentric circle closest to the wall 20, is half the diameter of the inner openings 40-47 that are more far away the wall 20 to provide a weaker gas stream. The different gas steams generate turbulences inside the plug device.
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Figure 4 shows a cut, view of the cylindrical cup 70 shown in Figure 3. The at least one channel 60 has a bigger cross-section, than each of the inner opening 40-57. The outer opening 32 is designed as a connection sleeve adapted to cooperate with a flexible tube that provide the pressurized gas.
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Figure 5 shows a plan view to the inner surface 140 of the part carrier 100. The cross section of the holes 120 in the part carrier 100, are smaller than the cross section of the inner openings 40-47, 50-53. The number of the holesi20 in the part carrier 100 is higher than the number of inner openings 40-47, 50-53. In this embodiment 12 inner openings 40-47, 50-53 and 20 holes 120 are disclosed. The number and diameter of the inner openings 40-47, 50-53 and the holes 120 has to be adapted to the small elongated parts 200. In this embodiment part carrier 100 has holding means 160 to hold the cylindrical cup 70 tight to the part carrier 100. The cylindrical cup 70 has corresponding holding means (not shown).
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Figure 6 shows a plan view to the outer surface 150 of the part carrier 100.
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Figure 7 shows a perspective, view to the inner surface 140 of the part carrier 100 with a plurality of unplugged and plugged small elongated parts 200. The part carrier 100 is shown after the pugging process. The plugging process provides a plurality of the small elongated parts 200 arranged with their second axis Y aligned along with the first axis X. The partly plugged small elongated parts 200 are provided to the worker. The worker is able to grab the small elongated parts 200 easy because they are fixed with the second end portion 204 in the holes 120 and protrude with the first end portion 202 in the air. The worker can grab them even blind. Even if not all small elongated parts 200 are plugged in the holes 120 while a process circle, it is an advantage in terms of work simplification and also cost reduction. The small elongated parts 200 are elongated along a second axis Y and comprise a first end portion 202 that has a bigger cross section than a second end portion 204. The cross section of the holes 120 is bigger than the cross section of the second end portion 204 of the small elongated parts 200. The cross section of the holes 120 is smaller than the cross section of the first end portion 202 of the small elongated parts 200. That's why the second end portions 204 fit into the holes 120 and the first end portions 202 does not.
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Figure 8 shows a perspective, more detailed, view to the small elongated arts 200. The small elongated parts 200 are elongated along the second axis Y and comprise a first end portion 202 that has a bigger cross section than the second end portion 204.
