Fixture eases the guided assembly of high reliability connectors

December 06, 2019 //By Julien Happich
reliability connectors
CAMI’s Light Director system is a CableEye accessory that provides a computer-guided technique for assembling connectors used in aerospace, medical, and other high-reliability applications.

This system uses LED-lit fibres to individually illuminate target cavities in the connector being assembled. When the technician enters the wire code printed on unconnected wires, or touches a wire connected at the other end, the CableEye software turns on the appropriate fibre, thereby causing a bright, flashing light to project from inside the target cavity guiding the technician to the proper insertion point. Correct insertion is confirmed by the elimination of light from that location, whereas insertion into an incorrect location leaves the flashing light visible.

Using synthetic speech, Light Director can read the pin number to the technician, further reinforcing the target location. Speech can be activated in English, Spanish, French, German, Chinese, Japanese, Korean, Polish or Turkish when a matching generic voice font has been downloaded. Speech recognition is also available as an option permitting the technician to speak wire codes to the system, thus eliminating the need for a keyboard or monitor.

Normally, technicians crimp pins on wires in advance of assembly to the connector. Wires may be identified during the assembly process by numeric code, bar code, color code, or if no codes are present, by electrical detection using a wrist-strap if the far end of the cable has already been assembled and can be electrically connected to the system. Field testing has shown that the Light Director greatly increases accuracy and assembly rate over manual methods while nearly eliminating errors. Because the Light Director greatly reduces the perceptual challenge of manually locating pin cavities in a complex connector, technician fatigue is greatly reduced, permitting a continuous, high productivity rate throughout the workday.

CAMI Research –

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