The Light Director system (patented) provides a new, computer-guided technique for assembling connectors used in aerospace, medical, and other high-reliability applications. This system uses light fibers 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, or touches a wire connected at the other end, the CableEye software turns on the appropriate fiber, 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.
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 doubles 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 work day.
The Light Director™ system is an accessory for CAMI's CableEye® PC-Based cable test system. Customers purchase a mounting kit for each mating connector consisting of a CableEye plug-in board with special LED sockets, LED light fibers, fiber guide boards, a connector support board, and hardware kit. All parts are reusable. Requires the AutoBuild Guided Assembly Software (Item 728).
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