Light-guided connection

Cami Research has introduced a computer-assisted technique for assembling circular connectors used in aerospace and other high-reliability applications.

The Light Director system uses light fibre driven by super-bright LED lamps to individually illuminate target cavities in the connector being assembled.

When the technician enters the wire code printed on unconnected wires, a computer program turns on the appropriate fibre 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 flash light visible.

The device also uses synthetic speech in English or Spanish to read the pin number to the technician, further reinforcing the target location.

Speech recognition is also available as an option permitting the technician to read wire codes to the system, thus eliminating the need for a keyboard or monitor.

Normally, technicians crimp pins on wires in advance of assembly. Wires may be identified during assembly by numeric code, bar code, colour 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.