New Connector Design Lowers Cost of Military Cable Assembly Processes

摘要

The new support terminal allows an operator to assemble wires without the use of pliers, testing can be achieved prior to soldering and connector joining can be mechanized. Manual operations are simplified in that there is no need for precise wrappings. Tacking permits assembly wiring without wire dislodgment usually encountered when wire ends are mechanically wrapped. Multiple connections can be accomplished and rework can proceed with ease. Assembly and inspector training is reduced with the improved terminal configuration. The new terminal increases flexure life by 200% over the cup type terminals. In the case of bifurcated terminals the flexure life rises to 500%. The flexure life of soldered connections with the support terminal is essentially equivalent to the flexure life of stranded wire from the spool. Thereas a 60% reduction in labor costs can be realized in the manual operation, wave soldering reduces the cost considerably more. Certain circular high wire density connectors have been known to require 30 hours for assembly. With flow soldering, and reduced wire tinning and preparation costs, the 30 hours can be reduced to less than one hour. One of the most significant advantages of soldering, as compared to welding and solderless connections, lies in the non-destructive test or inspection capability. Since solder joint assessment is fundamentally based on observation of flow characteristics an inspector need only to note the fact that flow to the window did occur. (Author)