Light tester simplifies cable assembly connection

CAMI Research Inc. has introduced a computer-assisted technique for assembling circular connectors used in aerospace and other high-reliability applications. The Light Director system uses light fibers driven by super-bright LED lamps to individually illuminate target cavities in the connector being assembled.

How the system works
When the technician inputs the wire code printed on unconnected wires, a computer program turns on the right fiber, causing a bright, flashing light to project the target cavity inside, which guides the technician to the proper insertion point. Correct insertion is confirmed by the elimination of light from that location; whereas insertion into an incorrect mark leaves the flashing light visible.

The Light Director also uses synthetic speech in English or Spanish to read the pin number to the technician. Speech recognition is also available as an option to allow the technician to read wire codes to the system, thus minimizing the need for a keyboard or monitor. "Field testing has shown that the system doubles assembly rate over manual methods while nearly reducing errors," the company said.

Compatibility to other system
The light tester works well with CAMI's CableEye PC-based cable test system. Customers purchase a mounting kit for each mating connector consisting of a plug-in board with LED sockets that attaches to the tester, LED light fibers, fiber guide boards and a connector support board. The CableEye tester checks cables and wire harnesses for opens, shorts and miswires; measures diode forward voltage; checks resistance values over the range of 0.3Ω to 10 MΩ, and tests conduction and isolation resistance against specified thresholds.

-Gina Roos
eeProductCenter