Field of the invention
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The invention concerns a computer-implemented method for generating an insert of a plug connector having individually labelled wire insert positions, an insert in a plug connector, a labelling element for connection to an insert as well as a plug connector with an insert.
Background
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Certain applications, e.g. signalling technology for railway, have cables with up to hundreds of individual wire strands that have to be inserted in specific positions of an insert of an electrical connector for establishing electrical connections in the connector. In the connectors used in these settings, assigning wires to the correct wire insert positions of an insert can be tedious work and the connection plans in the documentation become extensive and hard to read. Manual connection is prone to errors and hence results in misaligned connectors that require time consuming revision. Furthermore, particular connectors with customized configuration require use of customized wire insert positions but are sometimes only produced in small batches with the specific configuration of the insert. Manufacturing these small batches of inserts is inefficient and cost intensive. The invention relates specifically to inserts for industrial electrical connectors, sometimes also referred to as heavy-duty connectors, which are characterised by their robust design and use in difficult environmental conditions and under high mechanical stress.
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Against this background, the invention to be solved by the invention is to further develop a method to customize an insert in an electrical connector for a variety of applications, to allow for the production of small batches of customized inserts for use with a standard connector configuration and design and to facilitate wire insertion in the insert in a reproducible way and with reduced manufacturing complexity, also by allowing automated manufacture of the insert.
Summary
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The problem is solved by a computer-implemented method according to claim 1 an insert in an electrical connector according to claim 9, a labelling element according to claim 16 and an electrical connector according to claim 21.
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Preferred embodiments of the invention are subject of the dependent claims.
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The problem is solved in particular by a computer-implemented method for generating an insert of an electrical connector having individually marked wire insert positions, comprising the steps of providing an output data set containing information about wire insert positions to be occupied in the insert to a computing unit; processing the output data set by the computing unit to generate a control data set containing a position pattern of wire insert positions to be labelled in the insert; providing the control data set to the control unit of a device for transferring the position pattern to the insert or to a labelling element to be connected to the insert and controlling the device and transferring the position pattern to the insert or to the labelling element to be connected to the insert on the basis of the control data set. The method allows for automatization of a method for generating an insert of an electrical connector with individually marked wire insert positions which offers several advantages, particularly in the context of customized electrical connector inserts or connector inserts with a high number of wire connection positions. While the advantage is more pronounced in connectors with a high number of wires it also offers advantages in cases with only a low number if wires, in particular during manual assembly of connectors. The individual labelling saves assembly time since repeated consultation of a wiring diagrams or assembly directions is rendered moot as the wire insert positions clearly indicate which wire has to be inserted, e.g. by corresponding colour-coded or pattern-based labelling of the wires and wire insert positions. The method enables an automated and highly efficient process for labelling wire insert positions in complex inserts and with complex cable set-ups having a plurality of individual wires to be connected in the correct position to ensure proper function of the electrical connector. The automation reduces human error and aims at providing a customized and application-focused insert, in particular in on-demand production of customized connectors, that speeds up assembly processes and ensures consistent placement of wires into the correct insert positions, which is crucial for complex wiring configurations.
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The output data set is i.e. generated by a software application running on a computing unit or computing system comprising at least one processor and memory, which may be implemented as a local workstation, a networked server with sufficient processing power and data storage capabilities, or as a cloud-based application accessible through a secure connection over the internet. The software application processes digital input data including connector specifications which include dimensions, maximum number of available wire insert positions, physical arrangement constraints, and in some variants also blocked or unassignable wire insert positions. Additionally, wiring requirements such as wire types, diameters, and electrical characteristics are important input data. Also application-specific parameters such as environmental conditions, for example temperature and humidity known or derived by sensor measurements in the assembly plant, can be included in the input data to allow for optimal assembly conditions and adjustment of labelling speed (for example, adhesives work faster when the temperature is higher).
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Also industry standards and safety requirements to comply to can be part of the input data. Furthermore, the customization requirements such as color coding schemes, labeling preferences, identification methods, e.g. if a machine readable code is to be proffered, can be inputted.
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The software analyzes this input data via an optimization algorithm that takes into account at least one of the following technical considerations:
- Spatial constraints for placing the wires and/or labels on the insert.
- Electrical compatibility, which refers to ensuring that the wire connections maintain proper signal integrity, prevent electromagnetic interference between adjacent wires, and conform to electrical standards for the specific application. This includes considerations for voltage ratings, current capacity, impedance matching, and signal isolation requirements that must be maintained when wires are inserted into their designated positions in the connector insert.
- Mechanical feasibility to determine valid wire insert positions while identifying positions that must remain blocked or unassignable due to mechanical interference.
- Wire insertion speed optimization, which involves analyzing the physical layout of wire insert positions to minimize the distance and time required for wire placement, whether performed manually by an operator or through automated assembly systems. This includes optimizing the sequence of wire insertion to reduce hand or robotic arm movement between wire pickup locations and their corresponding insert positions, thereby minimizing assembly time and reducing operator fatigue in manual operations. The optimization may consider factors such as wire routing paths across the insert surface, grouping of related wire connections to minimize cross-over movements, and arrangement of wire insert positions to facilitate efficient pick-and-place operations. In automated systems, this optimization may include consideration of robotic arm reach limitations, acceleration and deceleration profiles, and collision avoidance paths to maximize throughput while maintaining precision. The algorithm may also account for wire flexibility and handling characteristics that affect insertion speed, such as wire stiffness, bend radius limitations, and the force required for insertion into specific positions.
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The software then generates a comprehensive mapping of all potential wire insert positions with their status (assignable or blocked) and associated metadata (position coordinates, wire specifications, coding information). This mapping is the basis for the output data set.
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The optimization algorithm could for example be a brute-force optimization, e.g. trying out many possible output data and then evaluating or simulating if they are suitable, ranking them by metrics such as compliance to the aforementioned rules and regulations, but also speed of assembly. Another implementation uses a constraint-based approach such as Mixed Integer Linear Programming (MILP) which efficiently handles the spatial and electrical constraints while optimizing wire placement. This algorithm systematically evaluates possible configurations against defined constraints to find an optimal solution that satisfies all technical requirements.
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Alternatively, a machine learning approach using Reinforcement Learning (RL) can be employed, where the algorithm learns optimal wire positioning through iterative training on simulated or known (already implemented) connector assemblies, progressively improving placement decisions based on reward signals tied to assembly efficiency and error reduction. The RL approach is particularly effective for complex connector configurations where traditional constraint-based methods may become computationally intensive.
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The output data set is processed further by the by the same or another computing unit as for generation of the output data set, Both applications (creating the output data set and converting it to the control data set) can be running on the same computing system in some variants.
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The computing unit can make use of the output data set to generate the control data set containing a position pattern of wire insert positions to be labelled in the insert. For example, it can use a comuterimplemented method to assign movements (of an actuator such as a robot arm) of the device for transferring the position pattern to the insert or to a labelling element, as well as instructions which labels to dispense, e.g. by printing or spraying or adhering of pre-manufactured labelling stickers. This way the control data set contains all instructions necessary for the device to label correctly. The control data set is then tranferred to the control unit of the device.
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The labeled wire insert positions streamline the manufacturing process by providing clear visual or machine-readable indicators for each connection point. This labelling simplifies the identification of the correct insert positions during the assembly of the electrical connector, reducing the risk of incorrect wiring and improving overall quality. The method allows for easy customization of connector inserts by generating unique position patterns tailored to specific wiring requirements. This adaptability is especially beneficial for applications requiring varying wire connection layouts, as it facilitates the production of connectors for different configurations without significant manual intervention. The ability to transfer position patterns directly onto inserts or labelling elements, based on the generated control data set, enhances the speed and accuracy of manufacturing processes. This increases productivity by minimizing manual labelling tasks and enables faster production cycles. The computer-implemented approach integrates seamlessly with automated manufacturing systems, supporting digital workflows. This ensures compatibility with existing production lines and facilitates further advancements in automated connector production and assembly.
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In some embodiments the insert is formed as an insulating body in an electrical connector. This allows for applying the method of the invention to an insulating body in an electrical connector in particular in relation to the functionality and manufacturing of customized electrical connectors with insulated wire connection positions. By providing the insert as an insulating body, the method ensures that each wire connection position is physically and electrically isolated, reducing the risk of short circuits or interference between adjacent wires. This is especially important in highdensity connectors, where multiple wires are closely arranged. The method's capability to automatically label and customize the wire insert positions in an insulating body further facilitates the automated assembly of connectors. The clear labelling of insulated wire positions enables robotic or automated systems to insert wires quickly and accurately into the correct positions without manual intervention, improving efficiency and reducing errors. The ability to generate customized position patterns within the insulating body allows to produce electrical connectors tailored to specific wiring configurations, in particular on-demand production of customized connectors. This provides flexibility in connector design while maintaining insulation standards, which is particularly useful for specialized applications or non-standard wiring layouts. The insulating body, when combined with the accurate wire labelling and placement facilitated by the method, contributes to the mechanical and thermal durability of the electrical connector. The method streamlines the manufacturing process by allowing to integrate both the customization of wire insert positions and the formation of an insulating body into a single, automated workflow. This reduces the complexity of producing insulated connectors and enhances overall production efficiency.
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In some embodiments the output data set contains information on a marking area of the insert, on a maximum number of available wire insert positions and on the physical arrangement of the wire insert positions in the insert. This allows for optimized use of space. By including data on the marking area of the insert and the maximum number of wire insert positions, the method allows for an efficient use of the available space within the electrical connector. This ensures that the layout of the wire insert positions is optimized while maximizing the number of connections that can be accommodated. The method enables easy customization, on-demand production of customized connectors and adaptation of the insert layout to different connector sizes and configurations. By processing information on the arrangement of wire insert positions, the system can dynamically adjust the placement and labelling of these positions, allowing for flexibility in the design of electrical connectors without the need for extensive manual reconfiguration. The ability to automatically process data on the arrangement and maximum number of wire insert positions enhances the utility of the method in producing complex connectors with multiple wiring configurations. This feature ensures that even highly intricate layouts are managed efficiently, reducing the likelihood of errors during automated or manual assembly, and improving overall accuracy. Providing detailed information on the wire insert positions and their arrangement streamlines the production process, as the control unit can generate accurate labelling patterns. This leads to faster and more efficient manufacturing cycles, minimizing the need for manual adjustments or corrections during production and later assembly. The method also ensures that the wire insert positions are arranged in a controlled and predetermined manner, which enhances quality control. By having clear information on the available insert area and the maximum number of positions, manufacturers can ensure that each connector is produced to exact specifications, reducing variability, and ensuring consistency in large-scale or on-demand production. The inclusion of information on the area of the insert and wire positions allows the method to scale easily for different connector types and sizes. This makes it suitable for a wide range of applications, from small, compact connectors to larger, more complex systems, all while maintaining high precision and customization.
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The output data set comprises position information of blocked or unassignable wire insert positions in the insert. This allows for identifying and labelling wire insert positions that are excluded from use during assembly. This minimizes the risk of incorrect wire placement, thereby reducing the likelihood of connection errors in the final product. The method also enables the customization of connectors with non-standard layouts, where certain wire insert positions may need to remain unassignable due to design constraints, specific applications, or safety requirements. This provides greater flexibility in creating connectors for specialized use cases without compromising on functionality or safety. The ability to automatically account for blocked or unassignable wire positions optimizes the manufacturing process by eliminating the need for manual oversight or reconfiguration. This improves production efficiency, particularly in high-volume manufacturing environments, by ensuring that the control system accurately handles complex insert layouts.
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In some embodiments the device for transferring the position pattern is designed as a printer, embossing machine, injection moulding tool and/or engraving device. This allows for flexibility in selecting the most appropriate manufacturing process for different materials and connector types. This versatility enables tailored production methods based on the specific requirements of the connector or insert. Each of the mentioned devices provides a high degree of precision in transferring the position pattern to the insert or labelling element. Whether through printing, embossing, or engraving, the method ensures that the wire insert positions are clearly and accurately marked, which enhances the clarity and reliability of the labelling. Depending on the application, in particular the use of an injection moulding tool or engraving device offers the advantage of creating permanent and durable markings that withstand harsh environmental conditions, such as temperature variations or mechanical stress, making the connectors suitable for demanding applications. The ability to use multiple types of devices (e.g., printers for high-speed, large-scale production or embossing and engraving for more specialized, durable applications) allows the method to scale effectively across various production volumes and needs, optimizing cost and efficiency. The method hence allows manufacturers to choose the most suitable marking technique depending on the desired outcome, whether it is high-resolution printed markings for visual clarity or deep, permanent embossing or engraving for enhanced durability.
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In some embodiments the output data set comprises coding information to be provided on the insert or the labelling element and/or adjacent to the wire insert positions, in particular a colour code, a 3D-element or a computer-readable code, in particular a 1D barcode, a matrix code, or a dot code to be printed or embossed in the insert or the labelling element to be connected to the insert. This allows for the addition of positioning information during production of the insert or the labelling element and supports customization of the insert or labelling element and the provision of visual or machine-readable labels to facilitate insertion of wires during assembly of the insert or the electrical connector provided therewith.
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The invention further provides a computer program product, comprising machine-readable instructions which, when executed by a processor, cause at least one computing unit to perform the method according to the invention as well as a computing unit comprising at least one read access to a computer-readable storage medium on which the computer program is stored. The computer program product ensures that the method is executed automatically by a computing unit, minimizing the need for manual intervention. This increases the speed and accuracy of the manufacturing process, especially when managing complex wire insert patterns and labelling. The computer program can be easily integrated into existing manufacturing systems and hardware, allowing seamless implementation of the method across different production environments.
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This compatibility improves flexibility and reduces deployment time. By using a computer program to control the execution of the method, the process becomes highly consistent and accurate, ensuring reliable results across multiple production cycles. This is beneficial in maintaining quality control and minimizing errors. The ability to store and execute the program on various computing units allows for scalability in production, from small batch manufacturing to high-volume production lines. This adaptability makes the method suitable for a wide range of applications and production scales. The computer program can be easily updated or modified to reflect changes in the wire insert positions, labelling requirements, or production processes. This ensures that the system remains adaptable to evolving manufacturing needs without requiring extensive hardware changes.
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The invention further provides an insert in an electrical connector comprising wire insert positions, obtained by a method according to the invention, wherein the insert comprises at least one label for an application-specific assignment of at least one wire insert position. This allows for the application-specific assignment of wires, enabling the connector to be tailored to the specific requirements of different applications, in particular in on-demand orders of customized inserts or connectors. This flexibility simplifies the assembly process and ensures that each wire is correctly inserted in its designated position. The presence of clear, application-specific labels on the insert reduces the time and effort required for wire installation, as it eliminates guesswork and the potential for errors. This is particularly beneficial in complex wiring configurations where precise wire placement is critical. By manufacturing the insert using the computer-implemented method, the labels are applied with high precision and consistency, ensuring that each wire insert position is accurately marked for its intended use. This improves the overall quality and reliability of the final product. The labelled insert minimizes the risk of wiring errors during assembly or installation, as it provides clear visual or machine-readable guidance for the correct placement of each wire. This increases the safety and functionality of the electrical connector in the end application. The invention also allows for the production of inserts or labelling elements with customizable labelling for various types of electrical connectors, making the method adaptable to a wide range of industries and applications.
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In some embodiments of the insert the label is applied to the insert, in particular printed on or incorporated into the insert, in particular embossed or lasered in. This allows for incorporating labels directly into the insert providing permanent and durable markings. The aforesaid methods ensure that the labels remain legible and functional over time, even in harsh environmental conditions such as exposure to heat, moisture, or mechanical wear. Applying labels through processes like laser engraving or embossing enables precise placement and clear definition of the wire insert positions. This precision is crucial for complex connectors requiring accurate wire assignments and ensures a high level of consistency across production batches. The ability to incorporate or apply labels directly onto the insert, particularly through methods such as printing or embossing, allows for easy customization of the wire insert positions for specific applications. This flexibility supports the production of connectors tailored to a wide variety of technical requirements, also when produced on-demand and in small batches, only. Labels applied through printing offer high visual clarity, making it easy for installers to identify wire positions at a glance, thereby simplifying assembly and reducing errors. The clarity of labelling also enhances the usability and functionality of the connector. The use of automated techniques like printing, embossing, or laser engraving can be easily integrated into existing manufacturing processes, enabling the efficient production of labelled inserts at scale. These methods streamline production while maintaining high-quality labelling.
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In some embodiments of the insert a labelling element connectable to the insert is provided and wherein the labelling element comprises the label.
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Using a separate labelling element allows for greater modularity. This enables the same basic insert to be used across multiple applications with different labelling requirements, simply by changing the connected labelling element. This enhances production flexibility and reduces the need for multiple insert variants. The ability to connect a customized labelling element to the insert allows for easy application-specific labelling without altering the core design of the insert. This simplifies the manufacturing process, making it more adaptable to varied customer needs and reducing design complexity. Since the labelling element is connected separately during manufacture, labels can be produced, also on-demand, and applied in parallel with the insert production. This streamlines the assembly process and can increase production speed, allowing for more efficient manufacturing workflows. In cases where labelling may need to be updated or changed, the use of a separate labelling element provides the advantage of easy replacement. The labelling element, being a distinct component, can be manufactured with high-quality materials and techniques to ensure durability and clear, visible labelling. This ensures that the wire insert positions remain easy to identify and resistant to wear over time. The labelling element can be produced using various methods, such as printing, embossing, or engraving, providing flexibility in the design and appearance of the labels. This ensures that the labelling meets functional requirements, depending on the application.
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In some embodiments of the insert the labelling element is configured as a printable or embossable film, in particular self-adhesive film or adhesive film.
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In connection with the invention the term "self-adhesive film" refers to films that are pre-coated with a layer of adhesive that allows them to be applied to a surface without needing an additional bonding agent.
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In connection with the invention the term "adhesive film" refers to films adhering to surfaces through physical bonding mechanisms, such as Van der Waals forces, without the use of a pre-applied adhesive. These films offer a clean, residue-free, and reusable adhesion solution.
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The use of printable or embossable films provides a highly customizable solution for labelling, allowing for precise marking of wire insert positions directly on the film. This enables manufacturers to adapt the labelling for various connector configurations and applications. Self-adhesive films, which come pre-coated with adhesive, offer the advantage of a quick and easy application, streamlining the manufacturing process by eliminating the need for separate adhesive application. This ensures efficient production while maintaining consistency and precision in labelling.
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Adhesive films that bond through van der Waals forces or similar physical bonding mechanisms offer a clean and chemical-free solution. These films stick without additional adhesives, providing a reusable and residue-free option that maintains strong adhesion without potential degradation over time.
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Both self-adhesive and adhesive films, whether sticking via chemical adhesives or physical forces like van der Waals forces, ensure that the labels are securely applied to the insert, providing long-term durability and resistance to environmental factors such as moisture, heat, or mechanical wear. Films that adhere via van der Waals forces provide eco-friendly and reusable options, as they do not rely on chemical adhesives. This makes them ideal for applications where clean removability, recyclability, or sustainability is important.
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In some embodiments of the insert the labelling element is made from a printable or embossable, in particular self-adhesive cellulose-based material. The use of cellulose-based material for the labelling element provides a highly cost-effective option for labelling wire insert positions. Cellulose-based materials are widely available and inexpensive compared to other labelling materials, making it an economical choice for large-scale production. Cellulose-based materials are easily printable and embossable, allowing for precise and detailed customization of labels. This flexibility ensures that application-specific information can be quickly and clearly added to the label, making it suitable for a variety of electrical connector configurations. In particular, self-adhesive cellulose-based materials streamline the manufacturing process by providing a pre-coated adhesive backing that allows the label to be applied directly to the insert without the need for additional adhesive steps. This reduces assembly time and increases production efficiency. Cellulose-based materials such as but not restricted to paper or craft paper are biodegradable and recyclable, making it an environmentally friendly choice for labelling. This is particularly beneficial for industries prioritizing sustainability or adhering to strict environmental regulations. Printable cellulose-based materials offer excellent print quality, ensuring that labels are clear, legible, and resistant to smudging during the manufacturing process. This enhances the usability and reliability of the labels for identifying wire insert positions. The use of embossable cellulose-based materials provides durable labelling options that maintain their integrity over time, even in moderate environmental conditions. Embossing creates labels that are not only visible but also tactile, making them easier to identify during assembly or maintenance.
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In some embodiments of the insert the label is designed as a colour code, a 3D-element or a computer-readable code, in particular 1D barcode, matrix code, or dot code. The use of colour codes or computer-readable codes such as barcodes and matrix codes allows for quick and accurate identification of wire insert positions. This minimizes human error during assembly, ensuring that wires are inserted into the correct positions, which is especially critical in complex electrical configurations. The inclusion of computer-readable codes (e.g., 1D barcodes, matrix codes, or dot codes) facilitates automated identification and verification processes in manufacturing and assembly lines. These codes can be scanned by machines, allowing for faster and more efficient processing, which is crucial for high-volume production environments. 3D elements provide a tactile and visual labelling solution that can be easily identified by touch or sight, even in low-light conditions or environments where visual clarity is limited. This enhances the usability of the connector in various applications, particularly where quick and easy wire positioning is essential. Use of colour codes, 3D elements, or computer-readable codes offers significant flexibility in designing labels that are tailored to specific customer requirements or application needs. This makes the method highly adaptable to a wide range of industries and connector configurations. 3D elements and embossed or engraved computer-readable codes provide durable labelling solutions that maintain their clarity and functionality over time, even in harsh environmental conditions such as heat, moisture, or mechanical stress. Matrix codes and dot codes allow for the encoding of large amounts of data in a compact space. This is especially advantageous for connectors with limited surface area, where maximizing the amount of information in a small space is essential.
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The provision of computer-readable codes also offers benefits when using support devices such as mixed-reality (MR) or virtual-reality (VR) devices (such as VR-/MR-glasses or lenses) during assembly. The device can be configured to read the codes of the insert or the labelling element and corresponding codes provided on the wires to be inserted and direct the operator to the correct wire insert position during assembly thus avoiding assembly errors and facilitating the work of the operator. The computer-readable codes can also ensure faster and more reliable inspection of the assembled connectors by automated, code-based evaluation of the final work result using the aforesaid mixed-reality (MR) or virtual-reality (VR) devices.
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The insert comprises positioning aids for the labelling element. The inclusion of positioning aids in the insert allows for aligning and applying the labelling element with high precision on the insert. This eliminates the risk of misalignment, ensuring that the labels correctly correspond to the designated wire insert positions, which is critical for accurate wiring. Positioning aids simplify and accelerate the application of the labelling element, allowing for faster and more efficient production processes. This reduces the need for manual adjustments during label placement, contributing to a more streamlined assembly workflow. By guiding the labelling element into a specific position, positioning aids ensure consistent placement across all inserts, improving the overall quality and uniformity of the manufactured connectors. This enhances the reliability of the final product, especially in high-volume manufacturing. Positioning aids make the labelling process more compatible with automated assembly systems, allowing machines to accurately and quickly apply the labels without the need for complex alignment mechanisms. This facilitates the integration of the method into manufacturing lines. The correct and consistent positioning of labels, aided by these positioning features, enhances the usability of the connector by ensuring that wire insert positions are clearly and accurately marked, reducing errors during installation and maintenance.
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The invention further provides a labelling element for connection to an insert according to the invention providing the aforementioned advantages.
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In some embodiments the labelling element is designed as a printable or embossable film, in particular self-adhesive film or adhesive film providing the aforementioned advantages.
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In some embodiments the labelling element is made from a printable or embossable, in particular self-adhesive cellulose-based material providing the aforementioned advantages.
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In some embodiments the labelling element a label on the labelling element is configured as a colour code, a 3D-element, or a computer-readable code, in particular a 1D barcode, a matrix code, or a dot code providing the aforementioned advantages.
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In some embodiments the labelling element comprises positioning aids for connection with the insert or electrical connector. The position aids can be configured as punctures, indentations or recesses that can mate with corresponding structures of the insert or a connector or connector housing to thus ensure alignment of the labelling element indicating the wire insert positions with the corresponding wire insert positions of the insert. This ensures consistent placement of the labelling element on the inserts, improving the overall quality and uniformity of the manufactured connectors and enhances the reliability of the final product, especially in high-volume manufacturing.
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The invention further provides a use of a labelling element according to the invention with an insert, in particular an insert according to the invention.
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The invention further provides an electrical connector with an insert according to the invention. The electrical connector benefits from the customizable insert, which allows for application-specific labelling of wire insert positions. This adaptability makes the connector suitable for a wide range of uses, accommodating various wiring configurations and industry requirements. The precise labelling and positioning of wire insert positions, facilitated by the inventive insert, ensures accurate wire placement and minimizes the risk of wiring errors. This improves the overall reliability and functionality of the electrical connector, particularly in complex or sensitive electrical systems. By integrating features such as positioning aids for the labelling element, the invention simplifies the assembly and labelling processes, leading to faster and more efficient production of the electrical connector. This is particularly advantageous in high-volume manufacturing environments where consistency and speed are critical. The use of durable labelling methods, such as embossing or laser engraving on the insert, enhances the longevity of the electrical connector by ensuring that the labels remain intact and legible over time, even in challenging environmental conditions. The insert of the invention, with features like computer-readable codes and positioning aids, is well-suited for integration into automated assembly systems, facilitating high-precision, high-speed production and reducing the need for manual intervention. The clear and accurately positioned labels on the insert improve the usability of the electrical connector, making installation and maintenance more straightforward and reducing the risk of incorrect wiring during these processes.
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In some embodiments the electrical connector, the insert is configured as an insulating body. By applying the labelling directly to the insulating body or connecting a labelling element to it, the method integrates both labelling and insulation in a single component. This reduces the number of parts and simplifies the manufacturing process, leading to greater production efficiency and lower costs. Labels applied directly to the insulating body, either through printing, embossing, or other methods, ensures that the labels remain clear and legible over time. The combination of precise labelling in the insulating body improves the safety of the electrical connector by ensuring that wires are inserted into the correct positions and properly insulated from one another, reducing the risk of electrical faults or short circuits. The application of the labelling directly to the insulating body or its attachment through a labelling element allows for a compact design, making efficient use of space. This is especially valuable in applications where space is limited. Labelling can be easily customized for specific applications by printing or embossing directly on the insulating body or attaching a customized labelling element. This provides flexibility to adapt to different wiring configurations or industry standards without changing the overall design of the insulating body. Clear, durable labelling on the insulating body simplifies the installation and assembly process by providing easily identifiable wire insert positions. This minimizes the risk of errors during wiring, improving the overall reliability and functionality of the electrical connector.
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The number of wire insert positions included in the insert and the number of related positions in the labelling element, as outlined in all embodiments and aspects above, is greater than 5, preferably greater than 10, most preferably greater than 15. As indicated above, the higher the number of wires and related (insert) positions, the more advantageous the invention becomes, as it reduces the time and reduces the risk of incorrectly assigning a wire to a corresponding insert position.
Brief description of the drawings
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Examples of embodiments of the invention are shown in the drawings and are explained in more detail below. It shows:
- Fig. 1 a perspective view of an insert for an electrical connector according to an embodiment of the present invention;
- Fig. 2 a top view of a labelling element for connection with an insert according to an embodiment of the present invention; and
- Fig. 3 schematically depicts the steps of computer-implemented method for generating an insert of an electrical connector according to an embodiment of the present invention.
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The figures contain partially simplified, schematic representations. In some cases, identical reference numerals are used for identical, but possibly not identical, elements. Different views of the same elements may be scaled differently. Directional indications such as "left, "right", "top" and "bottom" are to be understood with reference to the respective figure and may vary in the individual representations with respect to the object shown.
Detailed description of embodiments
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Fig. 1 illustrates a perspective view of an insert 10 for an electrical connector according to an embodiment of the present invention, featuring multiple wire insert positions 11 organized in a grid 12 layout. The insert 10 is manufactured using the computer-implemented method according to the invention. The insert 10 is configured as an insulating body for insertion in an electrical connector (not shown). Each of the plurality of circular openings 13 corresponds to a specific wire insert position 11. The insert 10 is divided into distinct zones 14a, b, each equipped with customizable labels 15 that guide the correct placement of wires 16 based on the specific application requirements. Openings 13' and 13" with restricted or blocked use can be specifically labelled to avoid insertion of wires 16 in these particular positions. The labelling of the wire insert positions 11 can be customized for different uses of the insert 10 and according to user requirements. The labels 15 may be printed or embossed directly onto the insert or provided on a separate labelling element 20 (cf. Fig. 2) for connection with the insert 10. Additionally, the labels 15 can be configured as various types of identification codes 17, such as color codes, matrix codes, or other computer-readable codes, such as 1D barcodes or dot codes. These flexible labeling options allow for both visual and machine-readable identification of wire insert positions 11, enhancing the accuracy of wire placement and the automation potential of the assembly process.
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In some zones 14a, b, color-coded sections may represent different wire groups, while other sections may use matrix codes 17 or similar coding methods to enable automated systems to identify the correct wire insert positions 11. The ability to customize the type of labelling used (colour code, barcode, matrix code, etc.) offers significant versatility, making the insert adaptable to various industries, automation systems, and wiring standards.
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The insert 10 also includes positioning aids 18, designed to assist the alignment of a separate labelling element 20 as depict in Fig. 2. These positioning aids 18 may take the form of raised features, indentations, or guides that ensure the labelling element 20 is correctly positioned and that wires 16 are inserted into their designated positions without misalignment. This is particularly useful in automated assembly processes, where consistency and precision are critical, as well as in manual assembly, where it helps reduce human error.
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Fig. 1 also displays a set of coloured wires 16 positioned above the connector insert 10, demonstrating the intended placement of wires 16 into their respective positions according to their colour or function. The customizable labels 15 or separate labelling elements 20, whether printed or embossed, are clearly aligned with the color-coded or coded sections, offering both visual and machine-readable guidance during the wire insertion process.
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By allowing for customizable, printed, or embossed labels 15 that can be configured as colour codes, matrix codes, barcodes, or similar, the invention enhances the adaptability of the connector insert 10 for various applications. The ability to use machine-readable codes enables automated systems to easily interpret and process wire connection information, increasing assembly efficiency and reducing the likelihood of errors.
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Fig. 2 depicts a top view of a labelling element 20 for connection with an insert 10 of an electrical connector according to an embodiment of the present invention. The labelling element 20 can be connected with a connector insert 10 as shown in Fig. 1 and replace the labels 15 applied directly on the insert 10 as described above. The labelling element 20 is configured as a grid 12, corresponding to the multiple wire insert positions 11 of the insert 10. Each position on the labelling element 20 is clearly marked to provide guidance on where individual wires 15 should be inserted into the insert 10. The wire insert positions 11 are labeled directly on the labelling element 20, which can be configured as a film or made from a cellulose-based material. The labelling can include various forms of codes 17 or codings, such as color coding, matrix codes, QR codes, or other machine-readable computer codes, enabling both visual and automated identification of wire positions. These codes 17 can be printed or embossed onto the labelling element 20, depending on the desired method of manufacturing and application requirements. When configured as a film, the labelling element 20 can be attached to the connector insert 10 using adhesives provided on the side 21 of the film facing the insert 10 or on the insert 10 or by adhesion provided by e.g. van der Waals forces or similar physical bonding methods, eliminating the need for chemical adhesives. Non-chemical bonding is particularly useful in applications where easy removal or repositioning of the labelling element 20 is required. Alternatively, the labelling element 20 can be made from self-adhesive cellulose-based or other materials, allowing for secure and permanent bonding to the insert 10 using a pre-applied adhesive layer.
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The labelling on the element provides application-specific information, ensuring that wires 16 are pushed through the labelling element 20 and inserted in their correct positions during the assembly process, once the labelling element 20 is connected to or attached on the insert 10. The use of codes 17, such as matrix codes, QR codes, and color coding allows for efficient and error-free wire 16 identification, either through visual inspection or by automated systems. The codes 17 may be scanned or visually checked to ensure the correct wire 16 is inserted into each corresponding position on the insert 10. The labelling element 20 can be provided as a closed film or cellulose-based material such as paper, that is pushed through by the wire 16 upon insertion only in the openings 11 intended for use.
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By marking each wire insert position 11 with clear, customizable labels and codes 17, the labelling element minimizes 20 the risk of incorrect wire 16 placement, improving both manual and automated assembly processes.
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The labelling element 20 can be attached to the insert 10 manually or in an automated process. Positioning aids 18, as depicted in Fig. 1, provided in or on the insert 10, ensure correct alignment and avoid positioning errors.
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Fig. 3 schematically depicts the steps of computer-implemented method for generating an insert 10 of an electrical connector according to an embodiment of the present invention. In a first step S1 an output data set containing information about wire insert positions 11 to be occupied by wires 16 in the insert 10 to a computing unit is provided. The output data set can be generated using data provide e.g. from a design software tool. In step S2 the output data set is processed by the computing unit to generate a control data set containing a position pattern of wire insert positions 11 to be labelled in the insert 10. In step S3 the control data set is provided or transferred to a control unit of a device for transferring the position pattern to the insert 10 or to a separate labelling element 20 that can be connected to the insert 10. In step S4 the device is controlled based on the information in the control data set and transfers the position pattern to the insert 10 or to the labelling element 20 connectable to the insert 10. The method allows for automatization of the generation of an insert 10 or a labelling element 20 of an electrical connector with individually marked wire insert positions 11 which offers several key advantages, particularly in the context of customized electrical connectors or connector inserts 10 with a plurality of wire insert positions 11. The method enables an automated and highly efficient process for labelling wire insert positions 11 in complex inserts 10 and with complex set-ups having a plurality of individual wires 16 to be connected in the correct position to ensure proper function of the electrical connector. The automation reduces human error and aims at providing a customized and application-focused insert 10 that speeds up assembly processes and ensures consistent placement of wires 16 into the correct insert positions 11.
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The method streamlines the manufacturing process and simplifies the identification of the correct insert positions 11 during the assembly of the electrical connector. The method also allows for easy customization of connector inserts 10 and/or labelling elements 20 by generating unique position patterns tailored to specific wiring requirements. The option of transferring position patterns directly onto inserts 10 or labelling elements 20, based on the generated control data set, enhances the speed and accuracy of manufacturing processes. The computer-implemented approach integrates seamlessly with automated manufacturing systems, supporting digital workflows.
Reference numerals
-
- 10
- insert
- 11
- wire insert position
- 12
- grid layout
- 13, 13', 13"
- opening
- 14a, b
- zones
- 15
- label
- 16
- wire
- 17
- code
- 18
- positioning aid
- 20
- labelling element
- S1
- step
- S2
- step
- S3
- step
- S4
- step