Device and Method for Assembling an Electrical Plug Connector

Abstract

A device for assembling an electrical plan connector on a first cable end and/or on a second cable end of an electrical cable having one or more inner conductors. The device has at least two independent processing modules for processing the electrical cable. The device also has a common transport unit for transporting the electrical cable between at least two of the processing modules along a transport direction.

Claims

1. An apparatus for assembling an electrical plug connector on a cable end of an electrical cable which has one or more inner conductors comprising: at least two mutually independent processing modules for processing the electrical cable; and a common transport device for transporting the electrical cable between at least two of the mutually independent processing modules along a transport direction (T); and wherein a feed device which can be driven independently of the transport device feeds the cable along a feed direction (X) to at least one of the mutually independent processing modules by way of a relative movement between the electrical cable and the respective processing module; and wherein the at least two mutually independent processing modules, the transport device, and the at least one feed device are clocked in a synchronized manner.

2. The apparatus as claimed in claim and further comprising: a control unit operatively communicating with at least one of the mutually independent processing modules to control and/or monitor the processing of the electrical cable by the respective processing module.

3. (canceled)

4. The apparatus as claimed in claim 1 and wherein the feed direction (X) deviates from the transport direction (T).

5. The apparatus as claimed in claim 1 and further comprising: workpiece carrier system with at least one workpiece carrier for the electrical cable (1a, 1b) in order to transport the electrical cable between the at least two mutually independent processing modules.

6. The apparatus claimed in claim 1 and further comprising: a gripper device having at least one gripper to transport the electrical cable between the at least two mutually independent processing modules and/or to position the electrical cable for processing in at least one of the mutually independent processing modules.

7. The apparatus as claimed in claim 1 and wherein the common transport device has a roller conveyor to assist manual transport of the electrical cable between at least two of the mutually independent processing modules.

8. (canceled)

9. The apparatus as claimed in claim 1 and further comprising: a control device to control and/or monitor assembly of the plug connector by the at least two mutually independent processing modules.

10. The apparatus as claimed in claim 1 and wherein the at least two mutually independent processing modules for processing the cable end form module groups with one another, in particular a first module group (M1), comprising processing modules for aligning, orienting, measuring and/or marking the cable.

11. The apparatus as claimed in claim 10 and wherein the common transport device transports the electrical cable between the individual module groups.

12. (canceled)

13. (canceled)

14. (canceled)

15. (canceled)

16. (canceled)

17. The apparatus as claimed in claim 1 and wherein one of the mutually independent processing modules is a stripping module for incising and pulling off a part of a cable component of the electrical cable, the stripping module having a rotary head which is rotatable about a central axis (M) and on which a blade and a counterholder for the electrical cable are arranged opposite one another and so as to be aligned with the central axis (M); and wherein the electrical cable is guided in the stripping module along the central axis (M), and wherein the blade can be fed in the direction of the central axis (M) to the electrical cable to generate a radial incision in the cable component of the electrical cable at a defined axial position.

18. The apparatus as claimed in claim 17, and where the stripping module has at least one pulling-off tool on the rotary head and which can be fed in the direction of the central axis to the electrical cable; and wherein the pulling-off tool is positioned relative to the blade such that, in order to pull off the section of the cable component, the pulling-off tool engages into the incision generated by the blade when the pulling-off tool has been fed to the electrical cable.

19. (canceled)

20. The apparatus as claimed in claim 1 and wherein one of the at least two mutually independent processing modules is a multiple fitting module configured to fit the electrical cable starting from one of the cable ends with two or more plug connector components of the plug connector; and wherein the multiple fitting module has chambers for receiving the individual plug connector components; and wherein the chambers in the multiple fitting module are arranged so that the plug connector components accommodated in the chambers form a common channel (K) with a common central axis (M).

21. The apparatus as claimed in claim 1 and wherein one of the at least two mutually independent processing modules is a single fitting module to fit the electrical cable with an elastic ring body at a defined axial position; and wherein the single fitting module has an inclined tube with an end face (S) which is inclined relative to a tube cross section (Q) of the inclined tube by an inclination angle (α), and the end face can be inserted into a passage bore of the ring body; and wherein the electrical cable can be positioned in the inclined tube by the feed device such that the ring body is situated at the defined axial position (P) on the electrical cable when the ring body is slipped off from the inclined tube onto the electrical cable.

22. The apparatus as claimed in claim 1 and wherein one of the at least two mutually independent processing modules is a press-in module and the press-in module has an advancing device to press the cable end, which has been prefabricated with an inner conductor contact element, of the electrical cable along an advancing direction (X) into a corresponding slot (75) of a housing assembly of the plug connector until the inner conductor contact element has reached a setpoint position (P.sub.S) within the housing assembly, and an optical sensor unit for detecting the actual position (P.sub.1) of the inner conductor contact element within the housing assembly while the electrical cable is being pressed in.

23. An apparatus as claimed in claim 1 and wherein the at least one feed device has a first transport module and a second transport module, and wherein the first transport module transports the cable end along the feed direction (X) into one of the mutually independent processing modules for processing the cable end, or the first transport module transports the said cable end counter to the feed direction (X) out of the respective mutually indepenent processing module; and wherein the second transport module is at a position spaced apart from the first transport module in the feed direction (X) and the second transport module transports the cable end along, or counter to, the feed direction (X); and wherein the first transport module has transport units which can be fed to the electrical cable, and the transport units are repositionable so that plug connector components applied to the cable end, which is to be processed, of the plug connector can pass through the first transport module while the second transport module is transporting the electrical cable.

24. (canceled)

25. The apparatus as claimed in claim 1 and further comprising: a sensor module to detect an axial actual position (P.sub.IST) of at least one inner conductor contact element, which is fastened to one of the inner conductors of the electrical cable, within a contact part carrier of the plug connector relative to an intended axial end position (P.sub.END).

26. (canceled)

27. (canceled)

28. (canceled)

29. A method for assembling an electrical plug connector on a cable end of an electrical cable which has one or more inner conductors, comprising the steps: providing at least two mutually independent processing modules; providing a common transport device that transports the electrical cable between at least two of the mutually independent processing modules along a transport direction (T); and wherein, the electrical cable is fed along a feed direction (X) to at least one of the mutually independent processing modules by way of a relative movement between the electrical cable and the respective mutually independent processing module; and wherein the at least two mutually processing modules, the common transport device, and the at least one feed device are clocked in a synchronized manner.

30-50. (canceled)

51. An apparatus for assembling an electrical plug connector on a cable end of an electrical cable which has one or more inner conductors, comprising: at least two mutually independent processing modules for processing the electrical cable; a common transport device for transporting the electrical cable between at least two of the mutually independent processing modules and along a transport direction (T); and wherein at least one feed device which can be driven independently of the common transport device feeds the electrical cable along a feed direction (X) to at least one of the mutually independent processing modules, for the processing thereof by way of a relative movement between the electrical cable and the respective mutually independent processing module; and wherein the feed direction (X) deviates from the transport direction (T); and wherein each processing module can be operated independently of the other processing modules; and wherein the at least two mutually independent processing modules, the common transport device, and the at least one feed device are clocked in a synchronized manner, such that the assembly of the plug connector by the individual processing modules is intercoordinated in terms of time, as a result of which the processing time for mass processing can be reduced.

52. An apparatus for assembling an electrical plug connector on a cable end of an electrical cable which has an inner conductor comprising: at least two mutually independent processing modules for processing the electrical cable; a common transport device for transporting the electrical cable between at least two of the mutually independent processing modules and along a transport direction (T); and wherein at least one feed device which can be driven independently of the common transport device feeds the electrical cable, for the processing thereof, along a feed direction (X) to at least one of the mutually independent processing modules by way of a relative movement between the electrical cable and the respective mutually independent processing module; and wherein the at least one feed device has a first transport module and a second transport module, and wherein the first transport module transports the cable end along the feed direction (X) into one of the mutually independent processing modules for processing the cable end or to transport said cable end counter to the feed direction (X) out of the mutually independent processing module; and wherein the second transport module is arranged at a position spaced apart from the first transport module in the feed direction (X) and the second transport module transports the cable end along, or counter to, the feed direction (X); and wherein the first transport module has transport units which can be fed to the electrical cable and the transport units are repositionable so that plug connector components that are applied to the cable end, of the plug connector can pass through the first transport module while the second transport module is transporting the electrical cable.

53. The apparatus as claimed in claim and wherein the feed direction (X) runs orthogonally with respect to the transport direction (T).

54. The apparatus as claimed in claim 1 and wherein the at least two mutually independent processing modules for processing the cable end form module groups with one another, in particular a second module group (M2), comprising processing modules for prefitting the cable with plug connector components of the plug connector.

55. The apparatus as claimed in claim 1 and wherein the at least two mutually independent processing modules for processing the cable end form module groups with one another, in particular a third module group (M3), comprising processing modules for stripping and processing cable components of the cable.

56. The apparatus as claimed in claim 1 and wherein the at least two mutually independent processing modules for processing the cable end form module groups with one another, in particular a fourth module group (M4), comprising processing modules for assembling plug connector components on the electrical cable.

57. The apparatus as claimed in claim 1 and wherein the at least two mutually independent processing modules for processing the cable end form module groups with one another, in particular a fifth module group (M5), comprising processing modules for inspecting and/or cleaning the cable end.

Description

[0885] In the figures, in each case schematically:

[0886] FIG. 1 shows an exemplary two-core electrical cable in a side view;

[0887] FIG. 2 shows the electrical cable of FIG. 1 in a front view;

[0888] FIG. 3 shows an exemplary single-core electrical cable in a side view before and after an alignment of the first cable end;

[0889] FIG. 4 shows a feed device and a cutting device for unrolling the cable from a cable drum and cutting it to length in accordance with a fabrication length;

[0890] FIG. 5 shows the first end of the electrical cable of FIG. 1 after a twisting of the inner conductors and a resulting length reduction;

[0891] FIG. 6 shows a cable fixed with both cable ends on a workpiece carrier, a laser for generating a marking on the cable sheath of the cable, an electronic assembly for configuring an electronic component on the cable sheath of the cable, and sensors for detecting the actual alignment;

[0892] FIG. 7 shows an actuator module for approximating the actual twist of the inner conductors to the setpoint twist;

[0893] FIG. 8 shows an exemplary displacement of the axial position of a plug connector component along the central axis of the cable owing to the length reduction;

[0894] FIG. 9 shows a stripping module for incising and pulling off a part of a cable component in a perspective view;

[0895] FIG. 10 shows the rotary head of the stripping module according to FIG. 9 in a perspective view;

[0896] FIG. 11 shows an exemplary single-core electrical cable with two stripped parts;

[0897] FIG. 12 shows a linear blade with a straight cutting edge and a stop for the cable;

[0898] FIG. 13 shows a circular blade with a stop for the cable;

[0899] FIG. 14 shows an M-shaped shaped blade for stripping a filler layer which jointly encases the inner conductors;

[0900] FIG. 15 shows a further advantageous blade for stripping a filler layer that jointly encases the inner conductors;

[0901] FIG. 16 shows an exemplary two-core electrical cable fitted with four plug connector components and multiple sheath clamps, in a side view;

[0902] FIG. 17 shows an exemplary single-core electrical cable fitted with three plug connector components and multiple sheath clamps, in a side view;

[0903] FIG. 18 shows a multiple fitting module in a sectional side view;

[0904] FIG. 19 shows a detail of the multiple fitting module according to FIG. 18 after the electrical cable has been led through the plug connector components;

[0905] FIG. 20 shows a detail of the multiple fitting module according to FIG. 18 during the removal of the electrical cable;

[0906] FIG. 21 shows two chambers of the multiple fitting module of FIG. 18 in a perspective sectional illustration;

[0907] FIG. 22 shows a multiple fitting module for assembling an electrical plug connector which has multiple electrical cables;

[0908] FIG. 23 shows an enhancement for a fitting module with a guide mandrel as an insertion aid for the cable;

[0909] FIG. 24 shows a single fitting module according to a first exemplary embodiment with an inclined tube, a slipping-off means and a support body, before the inclined tube is inserted into the ring body;

[0910] FIG. 25 shows the single fitting module of FIG. 24 after the inclined tube has been inserted into the ring body and after the cable has been positioned in the inclined tube;

[0911] FIG. 26 shows an exemplary slipping-oft means in a perspective illustration;

[0912] FIG. 27 shows a possibility for the pre-treatment of the cable before the fitting;

[0913] FIG. 28 shows a single fitting module according to a second exemplary embodiment with an actuator assembly for inserting the inclined tube into the ring body and with a single magazine for the ring bodies, before the inclined tube is inserted into the ring body;

[0914] FIG. 29 shows the apparatus of FIG. 28 while the inclined tube is being inserted into the ring body;

[0915] FIG. 30 shows the apparatus of FIG. 28 after the cable has been positioned in the inclined tube;

[0916] FIG. 31 shows the apparatus of FIG. 28 after the ring body has been slipped off onto the cable;

[0917] FIG. 32 shows the apparatus of FIG. 28 in a perspective illustration with a partially opened, two-part support body;

[0918] FIG. 33 shows a single fitting module for assembling an electrical plug connector which has multiple electrical cables, having two inclined tubes;

[0919] FIG. 34 shows a press-in module according to a first exemplary embodiment while two electrical cables are being inserted into respective advancing devices;

[0920] FIG. 35 shows the press-in module of FIG. 34 after the cables have been fixed in a respective holding device;

[0921] FIG. 36 shows the press-in module of FIG. 34 after the housing assembly has been fixed by a fixing device and while the front end of the first cable is being fed into the housing assembly by the first advancing device;

[0922] FIG. 37 shows the press-in module of FIG. 34 after the inner conductor contact element of the first cable has reached the setpoint position in the housing assembly;

[0923] FIG. 38 shows a preloading device of the press-in module with a telescopic ram for mechanically preloading a latching means within the housing assembly;

[0924] FIG. 39 shows the preloading device of FIG. 38 while the inner conductor contact element, by making contact with a button element of the telescopic ram, is triggering a removal of the telescopic ram from the displacement path of the inner conductor contact element;

[0925] FIG. 40 shows the preloading device of FIG. 38 while the sensor unit is monitoring the actual position of the inner conductor contact element within the housing assembly in the course of the further pressing-in of the cable end;

[0926] FIG. 41 shows the preloading device of FIG. 38 after the inner conductor contact element has reached the setpoint position within the housing assembly;

[0927] FIG. 42 shows a press-in module according to a second, preferred exemplary embodiment while the electrical cable is being inserted into the advancing device;

[0928] FIG. 43 shows the press-in module of FIG. 42 after the correctly positioned alignment of the cable in the starting position using the alignment aid;

[0929] FIG. 44 shows the press-in module of FIG. 42 alter the housing assembly has been fixed by the fixing device and after the cable has been fixed in the holding device;

[0930] FIG. 45 shows an exemplary plug connector with two electrical cables after both cables have been pressed in during the final assembly process;

[0931] FIG. 46 shows a feed device of the apparatus according to the invention with two transport modules while an electrical cable is being placed into the second transport module;

[0932] FIG. 47 shows the feed device of FIG. 45 while the electrical cable is being transported through the second transport module in the direction of the first transport module;

[0933] FIG. 48 shows the apparatus of FIG. 46 during the transfer of the cable to the first transport module for onward transport;

[0934] FIG. 49 shows the device of FIG. 46 during the feed of the cable into one of the processing modules by the first transport module;

[0935] FIG. 50 shows the apparatus of FIG. 46 while the cable is being moved out of the processing module by the first transport module;

[0936] FIG. 51 shows the apparatus of FIG. 46 during the further movement of the cable out of the processing module by the second transport module, while the transport rollers of the first transport module are open in order to allow the plug connector component to pass through the first transport module;

[0937] FIG. 52 shows the apparatus of FIG. 46 during the opening of the clamping bodies of the second transport module for the purposes of releasing the fitted cable;

[0938] FIG. 53 shows an enlarged side view of roller bodies of the second transport module for the transporting or mounting of a single electrical cable;

[0939] FIG. 54 shows an enlarged side view of roller bodies of the second transport module for the simultaneous transport or mounting of two electrical cables according to a first variant;

[0940] FIG. 55 shows an enlarged side view of roller bodies of the second transport module for the transport or mounting of two electrical cables according to a second variant;

[0941] FIG. 56 shows an electrical cable fastened to a workpiece carrier, two exemplary information carriers and also a control device and a global database for assigning documentation of the plug connector assembly process;

[0942] FIG. 57 shows an assembly module for assembling a contact part carrier while the contact part carrier is being pushed onto two inner conductor contact elements of the electrical cable;

[0943] FIG. 58 shows the assembly module of FIG. 57 together with a sensor module for detecting an axial actual position of the inner conductor contact elements within the contact part carrier;

[0944] FIG. 59 shows the assembly module of FIG. 57 during the assembly of a shielding sleeve on the contact part carrier;

[0945] FIG. 60 shows an actuation means, controlled by the sensor module, for actuating a secondary securing means of the contact part carrier;

[0946] FIG. 61 shows a quality monitoring module with two optical sensors and two lighting units for optical quality monitoring of the plug connector assembly process;

[0947] FIG. 62 shows a ring nozzle of a cleaning module in a plan view;

[0948] FIG. 63 shows a ring nozzle, provided with an ionizer, of a cleaning module in combination with a suction-extraction device in a side view;

[0949] FIG. 64 shows a cleaning module with a pulse-controlled nozzle;

[0950] FIG. 65 shows a cleaning module with a further nozzle in combination with a further suction-extraction device;

[0951] FIG. 66 shows a cleaning module with four drivable brushes;

[0952] FIG. 67 shows a cleaning module with a spiral brush;

[0953] FIG. 68 shows a cleaning module with two half-shells and two foils for carrying out an adhesion process;

[0954] FIG. 69 shows a cleaning module with a vibrator;

[0955] FIG. 70 shows a cleaning module with a nozzle in combination with a suction-extraction device in a closed housing;

[0956] FIG. 71 shows a first detail of an apparatus according to the invention for assembling the electrical plug connector according to a first exemplary embodiment with exemplary, mutually independent processing modules and with a transport device;

[0957] FIG. 72 shows a second detail, which adjoins the first detail along the transport direction, of the apparatus according to the invention of the first exemplary embodiment;

[0958] FIG. 73 shows a third detail, which adjoins the second detail along the transport direction, of the apparatus according to the invention of the first exemplary embodiment;

[0959] FIG. 74 shows a first detail of an apparatus according to the invention for assembling the electrical plug connector according to a second exemplary embodiment with exemplary, mutually independent processing modules and with a transport device;

[0960] FIG. 75 shows a second detail, which adjoins the first detail along the transport direction, of the apparatus according to the invention of the second exemplary embodiment; and

[0961] FIG. 76 shows a third detail, which adjoins the second detail along the transport direction, of the apparatus according to the invention of the second exemplary embodiment.

[0962] In FIG. 1, by way of example, a multicore cable 1a is illustrated in enlarged form in a side view. FIG. 2 shows a front view of the multicore cable 1a.

[0963] As illustrated in FIG. 1, the inner conductors 2 each extend from a first cable end 3 to a second cable end 4. The multicore electrical cable 1 a illustrated has already been partially prefabricated. The multicore cable 1a has a cable sheath 5 and a cable shielding braid 6 running under the cable sheath 5. A shielding foil may optionally run above the cable shielding braid 6 (not illustrated). The inner conductors 2 run below the cable shielding braid 6 within a filler layer 7. The two inner conductors 2 each have an electrical conductor 2.1 or a core which is encased by an insulation 2.2. In the course of the preceding fabrication steps, the electrical conductors 2.1 of the inner conductors 2 have already been exposed in the region of the inner conductor ends 2.3 at both cable ends 3, 4.

[0964] The inner conductor contact elements 8 are subsequently fastened to the exposed conductors 2.1, in particular by crimping (illustrated by way of example for the upper inner conductor 2 of the first cable end 3 illustrated in FIG. 1). Furthermore, the cable shielding braid 6 has, at the first cable end 3, been folded back over the cable sheath 5, preferably over a metal sleeve or support sleeve (not illustrated), and optionally fixed with a fabric tape 9. The right-hand cable end illustrated in FIG. 1 (in this case the second cable end 4) is still unprocessed, except for the exposure of the inner conductors 2 and the stripping of the conductors 2.1 in the region of the inner conductor ends 2,3.

[0965] The two-core cable 1a illustrated in the exemplary embodiment is to be understood merely as an example for use with the invention. In principle, the invention is suitable for use with any cable type, for example also for use with a multicore cable is with more than two inner conductors 2. However, the invention is also suitable for use with a single-core cable 1b, as will be shown below.

[0966] In the present case, the inner conductors 2 run in twisted fashion through the cable 10, for which reason, in the unprocessed state, in a manner dependent on the cable length (referred to here as the fabrication length L), there is an actual twist V.sub.IST between the inner conductor ends 2.3 emerging from the respective cable end 3, 4. The actual twist V.sub.IST is optionally detected for example by a control unit 10 (cf. for example FIG. 7). Furthermore, the control unit 10 can also detect the setpoint twist V.sub.SOLL for the inner conductor ends 2.3 emerging from the respective cable end 3, 4.

[0967] It may be provided in the course of the plug connector assembly process according to the invention that the control unit 10 determines an actual alignment A.sub.IST and a setpoint alignment A.sub.SOLL of the inner conductors 2 of the first cable end 3, wherein the first cable end 3 is aligned in order to approximate the actual alignment A.sub.IST to the setpoint alignment A.sub.SOLL, and wherein the aligned first cable end 3 is fixed on a workplace carrier 11 (cf. for example FIG. 6 or FIG. 71).

[0968] FIG. 2 illustrates, by way of example, an actual alignment A.sub.IST and a setpoint alignment A.sub.SOLL of the inner conductors 2 of the multicore cable 1a, wherein the state or the actual alignment A.sub.IST of the first cable end 3 before its alignment is illustrated by dashed lines. The alignments A.sub.IST, A.sub.SOLL relate to a radial alignment in relation to the longitudinal or central axis M of the cable 1. By twisting the multicore cable 1 along its central axis M, the actual alignment A.sub.IST can thus be approximated to the setpoint alignment A.sub.SOLL, as indicated in FIG. 2.

[0969] In particular, it may be provided that, for the fabrication of the multicore cable 1a, the setpoint alignment A.sub.SOLL of the inner conductors 2 of the first cable end 3 is determined by the control unit 10 in accordance with an assembly alignment of a plug connector component of a first plug connector 12 to be assembled on the first cable end 3 (cf. FIG. 73). The plug connector component may for example be a contact part carrier 13 (cf. for example FIG. 7, FIG. 8 or FIG. 57) which, owing to the process, can be pushed onto the inner conductor 2 of the multicore cable la only in one specified assembly alignment, for which reason an alignment of the first cable end 3 taking into consideration the assembly alignment may be advantageous.

[0970] In particular, for the fabrication of the multicore cable 1a, the setpoint alignment A.sub.SOLL of the inner conductors 2 of the first cable end 3 may be determined by the control unit 10 also taking into consideration a colour coding of the inner conductors 2 (for example black and red for defining the pin assignments ground or “minus” and “plus”).

[0971] Also taking into consideration the alignment of the inner conductors 2 of the second cable end 4 in the determination of the setpoint alignment A.sub.SOLL can be advantageous with regard to the multicore cable 1a, for example also in order to take into consideration a twist, to be described below, of the inner conductor ends 2.3 of the respective cable ends 3, 4.

[0972] As already mentioned, the invention is also suitable for the use or fabrication of a single-core cable 1b with only one inner conductor 2, for example in a coaxial design. A corresponding single-core cable 1b is illustrated by way of example in FIG. 3 in a side view.

[0973] In the course of the cable fabrication process or plug connector assembly process, it may be provided that a plug connector component of a second plug connector (not illustrated) is fastened, preferably fastened in twist-proof fashion, to the second cable end 4. By way of example, FIG. 3 illustrates an inner conductor contact element 8 which is cohesively connected to the inner conductor 2 of the single-core cable 1b.

[0974] The single-core cable 1b illustrated in FIG. 3 is to be understood purely as an example. The single-core cable 1b likewise has a cable sheath 5 and a cable shielding braid 6 running under the cable sheath 5.

[0975] The cable shielding braid 6 is folded over onto a support sleeve 15. The insulation 2.2 or the primary insulation of the inner conductor 2 runs under the cable shielding braid 6. The inner conductor 2 may for example be formed as a strand of multiple individual wires; in principle, however, the exact structure of the single-core cable 1b is not of importance.

[0976] In the course of the fabrication of the single-core cable 1b, it may be provided that, for example, the control unit 10 determines an actual alignment A.sub.IST and a setpoint alignment A.sub.SOLL of the plug connector component assembled on the second cable end 4 (in this case of the inner conductor contact element 8) of the second plug connector, wherein the first cable end 3 is subsequently aligned in order to approximate the actual alignment A.sub.IST to the setpoint alignment A.sub.SOLL, and wherein the aligned first cable end 3 is fixed on the workpiece carrier 11.

[0977] The method step of aligning the first cable end 3 is indicated by way of example in FIG. 3, wherein the upper part of FIG. 3 shows the plug connector component or the inner conductor contact element 8 in the actual alignment A.sub.IST and the lower part of FIG. 3 shows the plug connector component or the inner conductor contact element 8 in the setpoint alignment A.sub.SOLL. A twist of approximately 90° is provided as an example.

[0978] In principle, for the fabrication of the single-core cable 1b, it may be provided that the setpoint alignment A.sub.SOLL of the plug connector component or of the inner conductor contact element 8 of the second plug connector is determined by the control unit 10 taking into consideration an assembly alignment (for example a process-related assembly alignment) of a plug connector component, which is to be assembled on the first cable end 3, of a first plug connector and an intended setpoint twist V.sub.SOLL between the first plug connector 12 and the second plug connector.

[0979] Here, it may for example be taker into consideration that, in the course of the later ultrasound welding process or of a resistance welding process, the plug connector component or the inner conductor contact element 8 of the first plug connector 12 can be fastened to the inner conductor end 2.3 of the first cable end 3 only at one defined angle. The first cable end 3 can thus advantageously already be aligned in order to ensure an intended setpoint twist V.sub.SOLL between the plug connectors or their plug connector components.

[0980] An actuator device 16, which is communicatively connected to the control unit 10, may be provided for twisting or aligning the first cable end 3. The actuator device 16 is indicated in FIG. 3 as a black box together with the control unit 10. A corresponding actuator device 16 may also be provided for aligning the first cable end 3 of the multicore cable 1a.

[0981] In the course of the plug connector assembly process according to the invention, it may be provided that the electrical cable 1a, 1b is unrolled from a cable drum and cut to the defined fabrication length L. For this purpose, a conveying device 17 indicated in FIG. 4 may be provided. Furthermore, a cutting module 18, likewise indicated in FIG. 4, may be provided and configured to cut the electrical cable 1a, 1b to length in accordance with the fabrication length L.

[0982] In the course of the fabrication of the multicore cable 1a, provision may be made for the actual twist V.sub.IST of the inner conductor ends 2,3 emerging from the respective cable end 3, 4 to be approximated to a specified setpoint twist V.sub.SOLL by twisting the inner conductors 2 at at least one of the cable ends 3, 4. The twist can subsequently be fixed, for example by virtue of a contact part carrier 13 applied to the inner conductor ends 2.3 being fixed in twist-proof fashion to the cable sheath 5.

[0983] The approximation of the actual twist V.sub.IST to the setpoint twist V.sub.SOLL however results in a reduction of the total length or fabrication length L of the cable 1a, as can be seen for example from a comparison of FIGS. 5 and 1.

[0984] FIG. 5 illustrates, by way of example, a length reduction ΔL caused by the twisting of the first cable end 3, which on the one hand affects and correspondingly shortens the fabrication length L of the cable 1a, and on the other hand also affects the lengths of individual sections of the cable 1a, for example specified stripping lengths L.sub.A along which the inner conductors 2 and/or their cores or electrical conductors 2.1 have been exposed starting from their inner conductor ends 2.3.

[0985] In order to take the length reduction ΔL into consideration in the cutting of the electrical cable 1a to length, it may for example be provided that the length reduction ΔL caused by the later approximation of the actual twist V.sub.IST to the setpoint twist V.sub.SOLL is calculated already in advance by the control unit 10 before the cable 1a is actually cut to length. The length reduction ΔL can thus be taken into consideration, and the fabrication length L increased (for example by the length reduction Δ), in order to at least partially compensate the length reduction ΔL.

[0986] The control of the conveying device 17 and of the cutting device 18 by the control unit 10 is indicated by way of example in FIG. 4.

[0987] In FIG. 6, a workpiece carrier 11 for fixing the cable 1a, 1b is indicated by way of example. It may be provided that the second cable end 4 is also fixed on the workpiece carrier 11. Depending on the fabrication length L or the cable length, the cable 1a, 1b may preferably be fixed such that the cable 1a, 1b forms a U-shaped profile between the two cable ends 3, 4, as illustrated in FIG. 6. In this way, it is for example advantageously possible for processing of both cable ends 3, 4 to be provided in a sequential sequence.

[0988] Provision may be made whereby, after the fabrication of the first cable end 3, the cable 1a, 1b is turned over in order, by swapping the two cable ends 3, 4 on the workpiece carrier 11, to process the second cable end 4 in a second pass of the plug connector assembly process.

[0989] It is correspondingly then possible, in particular for the fabrication of the multicore cable 1A, for the control unit 10 to determine an actual alignment A.sub.IST and a setpoint alignment A.sub.SOLL of the inner conductors 2 of the second cable end 4, wherein the second cable end 4 is aligned in order to approximate the actual alignment A.sub.IST to the setpoint alignment A.sub.SOLL).

[0990] A turning-over module 19 may be provided for turning the cable 1a, 1b over. For example, the turning-over module 19 may effect a rotation of the workpiece carrier 11 through 180°. Any other turning-over of the cable 1a, 1b, and even manual turning-over of the cable 1a, 1b, may also be provided.

[0991] In the course of the plug connector assembly process, it may be provided, for example for quality assurance, that the first cable end 3 and/or the second cable end 4 is marked for documentation of the plug connector assembly process. FIG. 6 illustrates, by way of example, a laser 20 for applying an optical marking 21 (for example a barcode, a QR code or some other marking) to the first cable end 3.

[0992] A further example of a marking may be an electronic marking that is applied and/or configured on the cable 1a, 1b, as is likewise illustrated in FIG. 6. For this purpose, by way of example, an electronic assembly 22 may be provided which is able to configure a transponder 23 of an RFID system.

[0993] To detect the actual alignment A.sub.IST of the second plug connector assembled on the second cable end 4 and/or the actual alignment A.sub.IST of the inner conductors 2 of the first cable end 3, various sensors 24 may be provided and communicatively connected to the control unit 10. By way of example, FIG. 6 illustrates two cameras 25. In principle, however, any sensors 24 may be provided.

[0994] As already indicated above, it may also be provided in the course of the process of plug connector assembly on the multicore cable 1a that the control unit 10 detects the actual) twist V.sub.IST and the setpoint twist V.sub.SOLL of inner conductor ends 2.3 emerging from the respective cable end 3, 4. The actual twist V.sub.IST can be approximated to the setpoint twist V.sub.SOLL by twisting the inner conductors 2 at at least one of the cable ends 3, 4. The twist can subsequently be fixed by virtue of a contact part carrier 13 applied to the inner conductor ends 2.3 being fixed in twist-proof fashion to the cable 1a or to its cable sheath 5.

[0995] The contact part carrier 13 may for example be fixed in twist-proof fashion by being pressed directly onto the corresponding cable end 3, 4, for example indirectly or directly onto the cable sheath 5, preferably onto a support sleeve fastened to the cable sheath 5 or onto a cable shielding braid 6 folded back over the cable sheath 5.

[0996] It is particularly preferably provided that the contact part carrier 13 is fixed indirectly to the cable sheath 5 of the associated cable end 3, 4 by virtue of a shielding sleeve 26 (cf. for example FIG. 7 or FIG. 16) being assembled in twist-proof fashion on the contact part carrier 13 and being pressed, preferably crimped, on the corresponding cable end 3, 4, for example on the support sleeve (not illustrated) or on the folded-over cable shielding braid 6.

[0997] With regard to the approximation of the actual twist V.sub.IST to the setpoint twist V.sub.SOLL, it may be provided that the cable end 3, 4 is twisted, wherein the contact part carrier 13 is held in twist-proof fashion. Alternatively or in addition, it may also be provided that the contact part carrier 13 is rotated together with the inner conductor ends 2.3 received in the contact part carrier 13 and/or that the shielding sleeve 28 is assembled in twist-proof fashion on the contact part carrier 13 and is rotated together with the contact part carrier 13 and the inner conductor ends 2,3 received in the contact part carrier 13.

[0998] The shielding sleeve 26 and contact part carrier 13 preferably have a mechanical coding so as to be connectable to one another only in one or in two defined orientations. For example, a latching lug and a latching groove, as indicated in the following FIG. 7, may be provided.

[0999] In order to reduce the mechanical load on the multicore cable 1a, it may be provided that the control unit 10 determines a twist of both cable ends 3, 4, in particular if the actual twist V.sub.IST of the inner conductor ends 2.3 at the two cable ends 3, 4 deviates by more than 90° from the setpoint twist V.sub.SOLL. The control unit 10 can furthermore take an elasticity-induced backward twist V.sub.R of the inner conductor ends 2.3 into consideration in the approximation of the actual twist V.sub.IST to the setpoint twist V.sub.SOLL. The actual twist V.sub.IST can thus be approximated to the setpoint twist V.sub.SOLL by initially being overcompensated up to a twist composed of setpoint twist V.sub.SOLL plus a backward twist V.sub.R.

[1000] To detect the actual twist A.sub.IST it may be advantageous if the control unit 10 takes into consideration a lay of the inner conductors 2 that has been determined in advance, for example by measurement or experiment. Taking into consideration the fabrication length L or the cable length of the multicore cable 1a, it is thus possible, after the detection of the orientation of the inner conductor ends 2,3 at one of the two cable ends 3, 4, for the orientation of the inner conductors 2 at the opposite cable end 4, 3 to be calculated.

[1001] FIG. 7 shows, by way of example, a detail of an assembly module 29 for assembling the contact part carrier 13 on the inner conductor contact elements 8 of the multicore cable 1a, with some specific features shown only schematically.

[1002] The assembly module 29 has the said control unit 10 which, among other things, is also configured to detect the actual twist V.sub.IST and the setpoint twist V.sub.SOLL between the inner conductor ends 2.3 emerging from the cable ends 3, 4.

[1003] The assembly module 29 furthermore has an actuator module 30, which is communicatively connected to the control unit 10 and which is configured to twist the inner conductors 2 at at least one of the cable ends 3, 4 in order to approximate the actual twist V.sub.IST to the setpoint twist V.sub.SOLL in accordance with the specification of the control unit 10. A rotatable actuator module 30 with actuator clamping jaws 31 that can be fed to the contact part carrier 13 is illustrated by way of example. Also illustrated are cable clamping jaws 32 for fixing the multicore cable 1a at its cable sheath 5 in order to fix the multicore cable 1a in twist-proof fashion during the rotation of the contact part carrier 13. The actuator module 30 for rotating the contact part carrier 13 may also be an actuator module 30 which, in principle, is also used for linearly pushing the contact part carrier 13 onto the inner conductor contact elements 8 and/or for aligning the first cable end 3 for the purposes of approximating the actual alignment A.sub.IST to the setpoint alignment A.sub.SOLL.

[1004] The assembly module 29 may furthermore have a pressing tool 33 which is designed to fix the contact part carrier 13 to the cable sheath 5 of the cable la in twist-proof fashion in order to fix the rotation. The pressing tool 33 illustrated in FIG. 7 is in particular designed to crimp the shielding sleeve 26 after it has been assembled on the contact part carrier 13 in the region of the folded-over cable shielding braid 6. The shielding sleeve 26 has already been pushed onto the cable sheath 5 (as illustrated by dashed lines) in the course of a pre-assembly process and, after the rotation of the contact part carrier 13, can be pushed from the rear over the contact part carrier 13 in the corresponding orientation.

[1005] In order for the abovementioned length reduction ΔL during the approximation of the actual twist V.sub.IST to the setpoint twist V.sub.SOLL of the inner conductor ends 2.3 to be taken into consideration already during the exposure of the inner conductors 2, it may be provided that the axial length reduction ΔL caused by the later approximation of the actual twist V.sub.IST to the setpoint twist V.sub.SOLL is calculated already in advance by the control unit 10 before the inner conductors 2 are actually exposed at the corresponding cable end 3, 4. It is thus possible for the length reduction ΔL to be taken into consideration and for the stripping length L.sub.A, along which the inner conductors 2 are exposed starting from their inner conductor ends 2.3, to be increased (for example by the length reduction ΔL) in order to at least partially compensate the length reduction ΔL.

[1006] Here, the specified stripping length L.sub.A may be increased proportionally for the respective cable end 3, 4 by the calculated length reduction ΔL, if necessary with regard to defined tolerances. In principle, it may be desirable to fully compensate the length reduction ΔL. However, a partial compensation may also be sufficient if it is still within defined tolerance ranges.

[1007] It may be provided that only the specified stripping length L.sub.A of the inner conductors 2 to be exposed at the first cable end 3 is increased if only twisting of the first cable end 3 is provided. Accordingly, it may also be provided that only the specified stripping length L.sub.A of the exposed inner conductors 2 at the second cable end 4 is increased if only twisting of the second cable end 4 is provided. If both cable ends 3, 4 are twisted, provision may also be made for the specified stripping lengths L.sub.A to be increased at both cable ends 3, 4. In particular if only the total length or fabrication length L of the cable 1 is of importance, it is also possible, independently of the twisting, for the compensation of the length reduction ΔL to be provided at one of the cable ends 3, 4 or distributed across both cable ends 3, 4.

[1008] With regard to the length reduction ΔL, it can be a particular problem that this can influence the axial position, with respect to the central axis M of the cable 1a, of plug connector components or housing components that receive the inner conductors 2 (that is to say for example the contact part carrier 13) of what will later be the plug connector 12.

[1009] It is thus advantageously possible for the length reduction ΔL to be taken into consideration in the course of the plug connector assembly process in order to specify or correct an axial setpoint position P.sub.SOLL of a cable-side end 34 of a plug connector component that receives the inner conductors 2 within it, for example of the contact part carrier 13, along the central axis M of the cable 1a. The problem of the influencing the axial setpoint position P.sub.SOLL is illustrated by way of example in FIG. 8 for the contact part carrier 13.

[1010] It can be seen that the position of the rear or cable-side end 34 of the contact part carrier 13 is moved closer to the opposite cable end 3, 4 owing to the twist or approximation of the actual twist V.sub.IST to the setpoint twist V.sub.SOLL. The relative position of the cable-side end 34 of the contact part carrier 13 with respect to defined axial positions P.sub.1-4 along the central axis M or along structures of the cable 1 may thus deviate from a specification. The four positions P.sub.1-4 illustrated in FIG. 8 are to be understood merely as examples. It is often for example the case that the axial setpoint position P.sub.SOLL of the contact part carrier 13 relative to a support sleeve 15 applied to the cable sheath 5 of the cable 1a is relevant for the plug connector assembly process and must be adhered to within specified tolerances. This can be ensured by taking the length reduction ΔL into consideration.

[1011] The inner conductors 2 or their conductors 2.1 can be exposed in the course of the cable fabrication process by virtue of a part 5a, 2.2a, which encases the inner conductors 2 or the conductors 2.1, of at least one cable component of the cable 1a, 1b being removed (cf. FIG. 11). For example, a part 5a of the cable sheath 5 of the cable 1a, 1b may be stripped and/or a part of the outer conductor or the cable shielding braid 6 of the cable 1a, 1b may be stripped or folded back over the cable sheath 5 and/or a part of the dielectric filler layer 7 that jointly encases the inner conductors 2 may be stripped and/or a part 2.2a of the insulation 2.2 of the inner conductors 2 may be stripped.

[1012] To expose the inner conductor 2 or the conductor 2.1 or the inner conductors 2 or the conductors 2.1, a stripping module 35 may be provided, which is illustrated by way of example in FIG. 9.

[1013] In principle, the stripping module 35 may be of any desired construction. It is also possible for multiple stripping modules 35 of identical or different structure to be provided. For example, a respective stripping module 35 may be provided for each part 5a, 2.2a of the cable 1a, 1b to be removed. The structure described below is to be understood merely as an example.

[1014] The illustrated stripping module 35 has a rotary head 36 which is rotatable about a central axis M and a detail of which is illustrated in enlarged form in FIG. 10 for illustrative purposes. The rotary head 36 is designed as a disk, wherein a belt drive may be provided for rotating the rotary head 36.

[1015] In order to insert the cable 1a, 1b into the stripping module 35 along the central axis M, the stripping module 35 may have conveyor modules 38 for linearly conveying the cable 1a, 1b along a feed direction X. It may however also be provided that the feed device to be described below is used to feed the cable 1a, 1b into the stripping module 35. The rotary head 36 may preferably be arranged between two of the conveyor modules 38, as illustrated in FIG. 9. The cable 1a, 1b may preferably firstly be cut to length and subsequently stripped.

[1016] In particular, where reference is made below to components of the stripping module 35 that are arranged on the rotary head 36, said components may also be usable in the context of a stripping module 35 which has no rotary head 36 but, for example, merely a rigid fastening for the respective components.

[1017] To expose the inner conductors 2 along the specified or elongated stripping length L.sub.A, at least one blade 39 may be used to generate a radial incision in the cable component of the cable 1a, 1b. Furthermore, a counterholder 40 positioned opposite the blade 39 may be used, which fixes the cable 1a, 1b during the incising process.

[1018] In the exemplary stripping module 35, a blade 39 and a counterholder 40 for the cable 1a, 1b are arranged opposite one another, and so as to be aligned with the central axis M, on the rotary head 36 (see in particular FIG. 10). FIG. 9 shows the rotary head 36 merely in a simplified illustration, in which only the blade 39 is illustrated as being assembled on the rotary head 36. The blade 39 is capable of being fed in the direction of the central axis M to the cable 1a, 1b in order to generate a radial incision in the cable component of the cable 1a, 1b, for example in the cable sheath 5, at a defined axial position, in the exemplary embodiment according to FIGS. 9 and 10, the blade 39 is designed as a shaped blade. The blade 39 may however in principle have any desired cutting edge. The blade 39 may for example also have a linear structure or a straight cutting edge, as illustrated in FIG. 12. Furthermore, a circular blade 39′ may be provided (cf. FIG. 13). The circular blade 39′ may in particular be mounted without a drive and so as to be freely rotatable in order to be able to roll on the cable 1a, 1b during a rotation about the cable 1a, 1b.

[1019] The counterholder 40 forms an abutment that is adapted to the outer diameter of the cable component. The counterholder 40 may in principle form any desired abutment, in particular a tapering abutment, for example a V-shaped abutment or an abutment formed by rollers. In the exemplary embodiment, the counterholder 40 is likewise capable of being fed in the direction of the central axis M to the cable 1a, 1b. In principle, however, the counterholder 40 may also be arranged so as to be immovable (on the rotary head 36).

[1020] In order to create a cutting depth limitation, the counterholder 40 may be designed such that it forms a stop for the blade 39. The maximum depth T (cf. FIGS. 12 and 13) of the radial incision in the cable component can thereby be limited, and damage to further components of the cable 1a, 1b that are situated under the cable component can be prevented. As an alternative or in addition, the blade 39 itself may also have or form a stop for the cable 1a, 1b for the purposes of cutting depth limitation. By way of example, a linear blade 39 is illustrated in FIG. 12, wherein the cutting edge is assembled in a blade receptacle such that the blade receptacle or the blade 39 forms a stop which positively specifies a maximum depth T for the incising process. The circular blade 39′ may also have a stop, as illustrated by way of example in FIG. 13. For this purpose, the circular blade 39′ according to FIG. 13 has a cylindrical stop A, the radius of which is smaller than the radius of the cutting edge, in order to specify the maximum depth T for the incising process.

[1021] In principle, it may be provided that the blade 39 does not cut off the cable component or the part 5a, 2.2a completely and, for example, leaves behind individual webs or a radial inner ring. The part 5a, 2.2a may therefore initially not be completely cut off by the radial incision.

[1022] The rotary head 36 preferably rotates (cf. FIG. 10) while the blade 39 generates the incision, in order to generate a radially fully encircling incision.

[1023] It may furthermore be provided that, to expose the inner conductors 2, the stripping module 35 has at least one pulling-off tool 41 which engages into the incision generated by the blade 39 in order to at least partially pull the stripped part 5a, 2.2a off the cable 1a, 1b.

[1024] In the exemplary embodiment, two pulling-off tools 41 are arranged on the rotary head 36, wherein the pulling-off tools 41 are positioned relative to the blade 39 such that, in order to pull off the part 5a, 2.2a of the cable component, said pulling-off tools engage into the incision generated by the blade 39 when the pulling-off tools 41 have been fed to the cable 1a, 1b. The pulling-off tools 41 are arranged opposite one another and are each aligned with the central axis M. As illustrated, the pulling-off tools 41 are preferably arranged offset by 90° with respect to the blade 39 and the counterholder 40. In principle, however, the two pulling-off tools 41 may be arranged at any desired angle relative to the alignment of the blade 39 and of the counterholder 40.

[1025] Similarly to the blade 39, the pulling-off tools 41 may also be designed as shaped tools, in particular in order to be adapted to the inner diameter of the cable component. The pulling-off tools 41 may however also be of linear design.

[1026] The pulling-off tools 41, the blade 39 and the counterholder 40 are arranged adjacent to one another on the rotary head 36 and are each equally spaced apart from an end side of the rotary head 36 in order to converge in each case on the same axial point on the central axis M during a radial feed movement.

[1027] A respective dotted-guide device may be provided (not illustrated in any more detail) for the feed of the blade 39, of the counterholder 40 and/or of the at least one pulling-off tool 41 to the cable 1a, 1b. However, a rail system or some other system may also be provided (likewise not illustrated in more detail).

[1028] The rotary head 36 is preferably stationary while the part is being pulled off by the at least one pulling-off tool 41. To pull off the part, the cable 1a, 1b may, after the feed movement of the pulling-off tools 41, be at least partially pulled out of the stripping module 35 counter to the feed direction X along the central axis M in order to at least partially pull off the part 5a, 2.2a (partial pulling-off) or fully pull off the part 5a, 2.2a (full pulling-off) from the cable 1a, 1b.

[1029] As already mentioned, the stripping module 35 may however also be designed without a rotary head 36. For example, a rotary head 36 may not always be suitable for stripping a particular cable component. For example, a shaped blade 43 specially adapted to the geometry of the multicore cable 1a may be provided for stripping the filler layer 7, as indicated in FIG. 14.

[1030] The shaped blade 43 is approximately M-shaped or W-shaped so as not to damage the inner conductors 2 within the filler layer 7. Preferably, for the stripping of the filler layer 7, two mutually oppositely situated shaped blades 43 are provided in the manner shown in FIG. 14, which shaped blades are capable of being fed radially in the direction of the central axis M of the multicore cable 1a in order to cut into the filler layer 7.

[1031] The shaped blade 43 may have a respective semicircular recess for each inner conductor 2 of the cable 1a; in the exemplary embodiment, two semicircular recesses are provided, because the exemplary cable 1a has two inner conductors 2, as a result of which the cutting regions approximately follow an M or W shape.

[1032] It is however also possible for any other blade 39, 43 to be provided for the stripping of the filler layer 7, for example a blade 39 illustrated in FIG. 15, which does not follow the negative form of the inner conductors 2 arranged in the filler layer 7. By way of example, the blade 39 has a V-shaped cutting edge. A second, identically or similarly designed blade 39 may incise the cable 1a from the opposite side. The filler layer 7 can subsequently be torn off at the incision points or at the remaining webs in order to completely separate that part 5a, 2.2a of the filler layer 7 which is to be stripped. In this variant, it may be a particular advantage that the orientation of the blade 39 does not need to be adapted to the alignment of the inner conductors 2 in the cable 1a.

[1033] In the course of the plug connector assembly process, provision may be made for the cable sheath 5 of the cable 1a, 1b to be fitted with two or more plug connector components 26, 44, 45, 46, 47 starting from one of the cable ends 3, 4. The plug connector components may for example be the shielding sleeve 26 already described (cf. for example FIG. 16), a housing assembly or a plug connector housing 44 (cf. for example FIGS. 16 and 45), a line seal 45 (cf. for example FIG. 16 or FIG. 17), a cable retainer 46 (cf. for example FIG. 17), a retaining cap or end cap 47 (cf. for example FIG. 16 or FIG. 17) or an angle cap. In principle, the form of the plug connector component is not of importance in the context of the invention.

[1034] In the course of the pre-fitting of a two-core or multicore electrical cable 1a, it may however be the case in particular that fitting in accordance with the sequence illustrated in FIG. 16, of a shielding sleeve 26, followed by a socket housing or a plug connector housing 44, followed by a line seal 45, followed by a retaining cap 47 (or an angle cap in the case of an angled connector), is highly suitable. In the case of pre-fitting a single-core electrical cable 1b, fitting in accordance with FIG. 17 may be particularly suitable, according to which a line seal 45, followed by a cable retainer 46, followed by a retaining cap 47, are pushed onto the cable sheath 5 starting from one of the cable ends 3, 4.

[1035] It may be advantageous to ensure that the plug connector components 26, 44, 45, 46, 47 applied in the course of the pre-fitting remain in the desired axial positions along the central axis or longitudinal axis M of the cable 1a, 1b. For this purpose, it may be advantageous to surround each of the plug connector components 26, 44, 45, 44, 47 with two sheath clamps 48a, 48b, 48c, 48d in order to prevent an undesired displacement of the plug connector component 26, 44, 45, 46, 47 in both directions along the central axis M of the cable 1a, 1b. Depending on the plug connector component 26, 44, 45, 46, 47, the need for this may however also be omitted, for example if the plug connector component 26, 44, 45, 46, 47 is a seal, for example the line seal 45, which is generally already clamped sufficiently firmly on the cable sheath 5 of the cable 1a, 1b.

[1036] The sheath clamps 48a, 48b, 48c, 48d may for example be fastened to the cable 1a, 1b by means of a fitting unit.

[1037] In principle, different types of sheath clamps 48a, 48b, 48c, 48d may be provided. For example, the clamps 48a shown in FIG. 16 may be provided, which have an actuation region and a fastening region. By means of the actuation region, the clamps which are situated at the opposite end of two clamping limbs and which form the fastening region can be opened counter to the spring force of a resetting spring, and the damp 48a can thus be applied radially to the cable 1a, 1b. Alternatively, however, sheath clamps 48b with lashing elements 49 in the manner of a cable tie (cf. FIG. 17) may also be provided. A further exemplary sheath damp 48c, which has a metallic partial ring that can be clamped on the cable sheath 5, is likewise illustrated in FIG. 17. Furthermore, FIG. 17 shows a further exemplary sheath clamp 48d which has an elastic ring, for example a rubber ring, similar to a sealing ring. The exact design of the sheath clamp 48a, 48b, 48c, 48d is not of absolute importance in the context of the invention. Preferably, the sheath clamps 48a, 48b, 48c, 48d are fastened in non-positively locking and reversible fashion to the cable sheath 5 of the cable 1a, 1b.

[1038] The at least one sheath clamp 48a, 48b, 48c, 48d may optionally be removed again from the cable sheath 5 of the cable 1a, 1b after the plug connector assembly process.

[1039] FIG. 18 schematically illustrates, in a sectional side view, a multiple fitting module 50 for use in the course of a plug connector assembly process. The multiple fitting module 50 is configured to, for the plug connector assembly process, fit a cable 1a, 1b with one or more plug connector components 26, 44, 45, 46, 47 starting from a front, free end or starting from one of the cable ends 3, 4 of the cable 1a, 1b. The multiple fitting module 50 for the fitting of the two-core cable 1a is illustrated merely by way of example.

[1040] The multiple fitting module 50 has chambers 51 for receiving the individual plug connector components 26, 44, 45, 46, 47, wherein the chambers 51 are arranged such that the plug connector components 26, 44, 45, 46, 47 received in the chambers 51 form a common channel K (cf. illustration using dashed lines in FIG. 18) with a common central axis M.

[1041] As illustrated in the exemplary embodiment, the multiple fitting module 50 may have a magazine 52 in order to hold the plug connector components 26, 44, 45, 46, 47 ready for the fitting of further cables 1a, 1b. In the exemplary embodiment, a shaft-type magazine is illustrated; in principle, however, any magazine may be provided.

[1042] The chambers 51 of the multiple fitting module 50 may be arranged such that the plug connector components 26, 44, 45, 46, 47 received in the chambers 51 are spaced apart from one another along the central axis M at defined spacings. Depending on the respective plug connector component 26, 44, 45, 46, 47 and the subsequent assembly process, it may be provided that different plug connector components 26, 44, 45, 46, 47 are spaced apart from one another by different spacings, which may be specified for example by a corresponding wall thickness of the chambers 51 and/or of the magazine 52.

[1043] For example, a first spacing d.sub.1 may be provided between the foremost plug connector component (in the exemplary embodiment, the shielding sleeve 26) and the second plug connector component (in the exemplary embodiment, the plug connector housing 44), a second spacing d.sub.2 may be provided between the second plug connector component or the plug connector housing 44 and a third plug connector component (in the exemplary embodiment, the line seal 45) and a third spacing d.sub.3 may be provided between the third plug connector component or the line seal 45 and a fourth plug connector component (in the exemplary embodiment, the retaining cap 47). A defined spacing d.sub.4 the first plug connector component or of the shielding sleeve 26 to the front cable end 1a, 1b may also be provided when the electrical cable 1a, 1b has been fully pushed into the multiple fitting module 50. The spacings d.sub.1, d.sub.2, d.sub.3, d.sub.4 are ultimately reproduced on the fitted cable 1a (cf. FIG. 16).

[1044] Advantageously, the chambers 51 of the multiple fitting module 50 may furthermore be designed such that passage bores which run through the plug connector components 26, 44, 45, 46, 47 and which serve for receiving the cable 1a, 1b are aligned coaxially with one another when the plug connector components 26, 44, 45, 46, 47 have been received in the chambers 51. For this purpose, for example, the support surface or a lower base 53 of the multiple fitting, module 50 in the respective chambers 51 may have a depth respectively configured for the plug connector components 26, 44, 45, 46, 47, as illustrated in FIG. 18. In addition, it may be provided that the chambers 51 of the multiple fitting module 50 are designed to hold the plug connector components 26, 44, 45, 46, 47 in twist-proof fashion, in particular if a particular alignment or orientation of individual plug connector components 26, 44, 45, 46, 47 is provided in the course of the subsequent plug connector assembly process.

[1045] A feed device 54 may be provided (which need not necessarily be part of the multiple fitting module 50) in order to lead the cable 1a, 1b with its cable end 3, 4 along the central axis M through the plug connector components 26, 44, 45, 46, 47 in order to push the plug connector components 26, 44, 45, 46, 47 onto the cable sheath 5 of the cable 1a, 1b. The cable 1a, 1b can thus be led with its cable end 3, 4 along the central axis M through the plug connector components 26, 44, 45, 46, 47 until it reaches a predetermined end position P.sub.END, as illustrated in FIG. 19. In the exemplary embodiment, the feed device 54 has a roller conveyor device with two rollers, between which the cable 1a, 1b is guided in order to displace the latter linearly.

[1046] In order to monitor the position of the cable 1a, 1b along the central axis M, it is for example possible for a light barrier 55 or some other sensory device to be provided in order to identify when the electrical cable 1a, 1b has reached the end position P.sub.END in the multiple fitting module 50 and in order to stop the cable feed if necessary (cf. FIGS. 18 and 19). In principle, continuous detection of the position of the cable 1a, 1b may also be provided.

[1047] In particular, in order to prevent the plug connector components 26, 44, 45, 46, 47 from being displaced along the central axis M while the electrical cable 1a, 1b is being led through, it may be provided that the chambers 51 of the multiple fitting module 50 are designed to block the plug connector components 26, 44, 45, 46, 47 in the axial direction, in particular in the feed direction X (cf. arrow in FIG. 18) of the electrical cable 1a, 1b, along the central axis M in positively locking fashion. For this purpose, it is for example possible for the walls of the magazine 52 to be continued, wherein a corresponding cutout can allow the cable 1a, 1b to be led through.

[1048] In particular if the passage bores of the plug connector components 26, 44, 45, 46, 47 correspond or at least approximately correspond to the diameter of the cable sheath 5, it may be advantageous for at least one of the plug connector components 26, 44, 45, 46, 47 to be pushed onto the cable sheath 5 using a lubricant, preferably an alcohol or a silicone oil. For this purpose, provision may for example be made to provide the cable sheath 5 and/or the plug connector component(s) 26, 44, 45, 46, 47 with a lubricant.

[1049] In the course of the fabrication of the electrical cable 1, the latter is generally cut to length from a so-called endless cable in accordance with the intended length.

[1050] A suitable fitting method may be carried out by means of a computer program product with program code means on the control unit 10 of the multiple fitting module 50, as indicated in FIGS. 18 and 19.

[1051] The cable 1a, 1b fitted with the plug connector components 26, 44, 45, 46, 47 may, after the cable 1a, 1b has been led through the plug connector components 26, 44, 45, 46, 47, be removed from the multiple fitting module 50 for example laterally with respect to the feed direction X of the cable 1a, 1b or counter to the feed direction X of the cable 1a, 1b, as indicated in FIG. 20.

[1052] In FIG. 21, a detail of the multiple fitting module 50 is illustrated in enlarged form in a perspective sectional illustration. The detail shows, by way of example, two chambers 51 of the multiple fitting module 50. The chambers 51 are separated from one another by partition walls 51.1, which may have different wall thicknesses in order to realize the spacings d.sub.1, d.sub.2, d.sub.3, d.sub.4. The partition walls 51.1 simultaneously serve as a stop for the plug connector components 26, 44, 45, 46, 47 that have been placed into the chambers 51 (said plug connector components have been omitted from FIG. 21). The partition walls 51.1 are furthermore designed to leave a recess around the central axis M, in the region of the channel K, for the leadthrough of cable 1a, 1b through the plug connector components 26, 44, 45, 46, 47. The base 53 of the multiple fitting module 50 has steps in order to provide different height levels for the respective plug connector components 26, 44, 45, 46, 47 within the chambers 51 in order to make possible a continuous channel K or coaxial positioning of the plug connector components 26, 44, 45, 46, 47. In order to prevent the plug connector components 26, 44, 45, 46, 47 from falling out laterally, side walls may also be provided. In the exemplary embodiment, only one rear side wall 51.2 is provided in order that the fitted cable 1a, 1b can still be removed laterally from the multiple fitting module 50, as indicated in FIG. 20. The magazine 52 (omitted in FIG. 21) arranged above the multiple fitting module 50 however preferably has side walls on both sides. The base 53, the side wails and/or the partition walls 51.1 may optionally be designed to hold the plug connector components 26, 44, 45, 46, 47 ready in a predefined alignment or orientation.

[1053] FIG. 22 shows, in a sectional illustration from above, a detail of a multiple fitting module 50 for assembling an electrical plug connector 12 which has multiple electrical cables 1a, 1b (cf. for example FIGS. 45 and 76). The multiple fitting module 50 is designed to fit a cable sheath 5 of the respective cable 1a, 1b with two or more common plug connector components 56. The principle is illustrated by way of example on the basis of a common line seal 56. A common plug connector component 56 may however in principle be any plug connector component, in particular one of the plug connector components 26, 44, 45, 46, 47 already described above. The common plug connector component or the common line seal 56 has a number of passage bores 57 corresponding to the number of cables 1a, 1b.

[1054] In the exemplary embodiment according to FIG. 22, the fitting of a first electrical cable 1a, 1b and of a second electrical cable 1a, 1b with a common line seal 56 is demonstrated merely schematically. The number of cables 1a, 1b and the number of passage bores 57 and also the geometry and design of the plug connector component or of the line seal 56 are not to be understood as limiting.

[1055] The common line seal 56 is arranged in the multiple fitting module 50 in the chamber 51 assigned thereto such that the line seal 56, together with further plug connector components (not illustrated), forms a common channel K with a common central axis M for each of the cables 1a, 1b. Correct orientation may be particularly important here in order to correctly align the passage bores 57.

[1056] The cables 1a, 1b may be led simultaneously or successively through the corresponding plug connector components 56 by the feed device 54 in order to push the plug connector components 56 onto the cables 1a, 1b or onto the cable sheaths 5 thereof. The cables 1a, 1b are preferably led simultaneously through the plug connector components 56, which can for example simplify the construction of the feed device 54. Provision may however also be made, in particular in the case of plug connector components 56 with very narrow passage bores 57 in relation to the cable diameter of the cable 1a, 1b (for example in the case of a common line seal 56), to lead the cables 1a, 1b through successively in order to reduce the forces that arise during the pressing-in of the cables 1a, 1b.

[1057] The multiple fitting module 50 can be constructed substantially as already described above. Corresponding partition walls 51.1 may be provided in order to support the line seal 56 or the plug connector components, as has likewise already been shown. In addition to lateral support regions, the partition walls 51.1 may also have a central support region 51.1′ in order to provide even better support for the common line seal 56 or plug connector component for the insertion of the second cable 1a, 1b.

[1058] Finally, FIG. 23 shows a variant of a fitting module, in particular of a multiple fitting module 50, in which a guide mandrel 58 is provided as an insertion aid for the cable 1a, 1b. This variant is suitable for use with any fitting module and for the fitting of one or more cables 1a, 1b with any plug connector components 26, 44, 45, 46, 47, 56, and is shown merely by way of example, and in the form of a detail, for the fitting of the cable 1a, 1b with a line seal 45.

[1059] The guide mandrel 58 may, before the cable 1a, 1b is inserted, be led, from the direction opposite to the feed direction X of the cable 1a, 1b, through the plug connector components 26, 44, 45, 46, 47 received in the chambers 51. Here, the guide mandrel 58 may be led through all or only through some of the plug connector components 26, 44, 45, 46, 47. The guide mandrel 58 is preferably led through all of the plug connector components 26, 44, 45, 46, 47.

[1060] In order to be led more easily through the plug connector components 26, 44, 45, 46, 47, the guide mandrel 58 may be bevelled, or have a chamfer, at its front end.

[1061] The guide mandrel 58 may finally have a guide ring at its front end for the purposes of guiding the cable 1a, 1b. The guide ring may transition into the (optionally provided) chamfer, as illustrated in FIG. 23.

[1062] The cable 1a, 1b can finally be led through the plug connector components 26, 44, 45, 46, 47 while the guide mandrel 58 is simultaneously withdrawn and/or pushed back from the cable 1a, 1b. Here, the cable 1a, 1b is preferably in contact with the front end face of the guide mandrel 58.

[1063] The guide mandrel 58 is advantageously able to guide the cable 1a, 1b through the plug connector components 26, 44, 45, 46, 47. Furthermore, the guide mandrel 58 may already widen plug connector components 26, 44, 45, 46, 47 which have a very narrow passage bore 57, as a result of which the cable 1a, 1b can be led through these more easily.

[1064] A lubricant may be applied to the guide mandrel 58. The guide mandrel 58 is preferably formed from a metal or from a hard plastic.

[1065] FIG. 24 shows a single fitting module 59 for the pre-fitting of the cable 1a, 1b with one or more plug connector components 26, 44, 45, 46, 47 in the course of the plug connector assembly process according to a first exemplary embodiment in a sectional illustration. The single fitting module 59 may be used to fit the cable 1a, 1b with an elastic ring body 45, in the exemplary embodiment the line seal 45, of a plug connector 12 that is to be assembled on the cable 1a, 1b.

[1066] The elastic ring body 45 can in principle be any plug connector component 26, 44, 45, 46, 47 of the plug connector 12 or, for example, also one of the aforementioned sheath clamps 48a, 48b, 48c, 48d for fastening to the cable 1a, 1b. The sheath clamp 48a, 48b, 48c, 48d, which is generally independent of the plug connector 12, may for example be used in the course of the plug connector assembly process to mark, the cable 1a, 1b and thereby identify it and/or to secure plug connector components 26, 44, 45, 46, 47 that have been applied to the cable 1a, 1b, in particular loosely preassembled plug connector components 26, 44, 45, 46, 47, against slipping (as already mentioned).

[1067] In a first method step of the single fitting process, provision may be made for an inclined tube 60 with a bevelled end section E, or with an end face S which is inclined relative to a tube cross section Q of the inclined tube 60 by an inclination angle α, to be inserted into a passage bore 57 of the ring body 45. The tube cross section Q is aligned perpendicular to the longitudinal axis L.sub.S of the inclined tube 60. The end section E of the inclined tube 60 according to the first exemplary embodiment is, by way of example, bevelled linearly. The inclination angle α between the tube cross section Q and the end face S of the inclined tube 60 is, by way of example, approximately 45° in the exemplary embodiments. The inclination angle α may however in principle assume any value, in particular 10° to 80°, preferably 20° to 70°, particularly preferably 30° to 60° and very particularly preferably 40° to 50°.

[1068] Provision may advantageously be made to position the inclined tube 60 so as to be axially offset with respect to the ring body 45 before and at least partially during the insertion of the inclined tube 60 into the ring body 45. A corresponding axial offset is provided in all of the illustrated embodiments. In principle, however, a coaxial alignment may also be provided.

[1069] In order to support the ring body 45 during the insertion of the inclined tube 60, a support body 61 may be provided which may have a passage bore in order to be able to lead the cable 1a, 1b through during the fitting process. The ring body 45 may thus be supported, by way of its side facing away from the inclined tube 60, on the support body 61 while the inclined tube 60 is being inserted into the ring body 45 counter to the feed direction X of the cable 1a, 1b (indicated by an arrow in FIG. 25).

[1070] In order to assist the insertion of the inclined tube 60 into the ring body 45, provision may optionally be made for a lubricant, preferably an alcohol or a silicone oil, to be applied to the inclined tube 60 and/or to the ring body 45.

[1071] FIG. 25 illustrates the single fitting module 59 of FIG. 24 after the inclined tube 60 has been inserted into the ring body 45. Furthermore, the feed device 54 (for example a roller conveyor with two rollers) is illustrated, in order to position the cable 1a, 1b in the inclined tube 60 such that the ring body 45 is situated at a defined axial position P on the cable 1a, 1b when the ring body 45 is slipped off from the inclined tube 60 onto the cable 1a, 1b. In order to position the cable 1a, 1b as exactly as possible, a sensor unit (not illustrated in any more detail) may for example be provided.

[1072] A single-core cable 1b is illustrated in FIGS. 25, 30 and 31 merely in order to illustrate the functional principle of the single fitting module 59. In principle, any cable 1a, 1b, in particular also the multicore cable 1a, may be pre-fitted with a plug connector component 26, 44, 45, 46, 47, 56 by means of the single fitting module 59. For the purposes of a better illustration, the cable 1b is shown in FIG. 25 in a non-sectional view and is shown in FIGS. 30 and 31 in section along its central axis M. In FIG. 25, the electrical cable 1b has been partially stripped. In principle, however, the cable 1a, 1b may also still be in completely unprocessed form during the fitting process, as shown in FIGS. 30 and 31. In principle, however, the exact structure and the processing state of the cable 1a, 1b are not of absolute importance.

[1073] The cable 1b illustrated in FIG. 25 has, by way of example, already been pre-fitted with the cable retainer 46 and with the end cap 47. In the course of the single fitting process, the line seal 45 may now also be applied to the cable sheath 5 of the cable 1b.

[1074] In FIG. 25, the cable 1b has been positioned in the inclined tube 60 with the defined axial position P at the end of the end face S or at the end section E of the inclined tube 60. After the positioning, the ring body 45 may be slipped off from the inclined tube 60 onto the cable 1b or onto the cable sheath 5.

[1075] A slipping-off means 62 may be provided for the slipping-off of the ring body 45. In the exemplary embodiment of FIGS. 24 and 25, a slipping-off means 62 is provided which encircles the inclined tube 60 in ring-shaped fashion and which, for the slipping-off of the ring body 45, is moved in the direction of the end face S of the inclined tube 60 or in the insertion direction. The slipping-off means 62 may advantageously have already been assembled on the inclined tube 60 in advance, as illustrated in FIG. 24. The slipping-off means 62 may optionally have, at its end facing towards the ring body 45, a section 63 which tapers conically in the direction of the ring body 45, as illustrated in FIG. 26.

[1076] In the course of the fabrication of the electrical cable 1a, 1b or in the course of the plug connector assembly process, the cable 1a, 1b is generally cut to length from a so-called endless cable in accordance with the intended fabrication length L. The cutting of the cable 1a, 1b may in particular have the result that the cable sheath 5, owing to its elasticity, spreads apart or expands at the cable end 3, 4, which can make it difficult to insert the cable 1a, 1b into the inclined tube 60 with an accurate fit. In order to simplify the insertion of the cable 1a, 1b or the positioning of the cable 1a, 1b in the inclined tube 60, provision may be made for this reason for the cable 1a, 1b to be bevelled or pointed, or provided with a chamfer 64, at its cable end 3, 4 in order to remove the radially protruding sections, as highlighted in FIG. 27.

[1077] FIG. 28 illustrates a particularly advantageous exemplary embodiment of the single fitting module 59. The functional principle will be explained on the basis of the fitting steps shown in FIGS. 28 to 32.

[1078] The inclined tube 60 has, for example, a concavely curved bevelled end section E. The inclination angle α may, in the case of a non-linearly running end section E, be defined by a chord running through the end points of the curve (as indicated by dashed lines).

[1079] By contrast to the inclined end face S of the exemplary embodiment shown in FIGS. 24 and 25, the walls of the inclined tube 60 in the exemplary embodiment of FIGS. 26 to 32 are not bevelled. In order to be inserted into the ring body 45, the inclined tube 60 is fastened to an actuator assembly 65, which has a telescopically extendable section for the linear feed of the inclined tube 60 along its central axis or longitudinal axis L.sub.S.

[1080] The single fitting module 59 illustrated in FIGS. 28 to 32 has a single magazine 66 in order to hold further ring bodies 45 ready for the fitting of further cables 1a, 1b. The single magazine 66 opens into a fitting chamber 67 in which the fitting of the cable 1a, 1b primarily occurs. Again, a support body 61 is provided on which the ring body 45 may be supported with its side facing away from the inclined tube 60 during the insertion of the inclined tube 60. That wall of the support body 61 which is provided for support is of oblique form such that, during the insertion of the inclined tube 60, the ring body 45 can tilt in the direction of its side facing away from the inclined tube 60. In this way, the insertion of the inclined tube 60 can be further simplified. For this purpose, the support body 61 may form a corresponding support angle that defines the tilt. The support body 61 has a passage bore for the insertion of the cable 1a, 1b into the single fitting module 59. A funnel section is provided in the support body 61 for easier insertion.

[1081] In the exemplary embodiment of FIGS. 28 to 32, the slipping-off means 62 is formed as a wall with a recess through which the inclined tube 60 can be guided and by which the inclined tube 60 can be supported.

[1082] FIG. 29 shows the state of the single fitting module 59 during the insertion of the inclined tube 60 into the ring body 45. FIG. 30 shows a state of the single fitting module 59 in which the cable 1a, 1b has already been positioned in the inclined tube 60. The defined axial position P of the cable 1a, 1b is in this case aligned with the end side of the slipping-off means 62.

[1083] In order to slip the ring body 45 off the inclined tube 60 onto the cable 1a, 1b or onto the cable sheath 5, the inclined tube 60 may be pulled out of the single fitting module 59 again by means of the actuator assembly 65 by retraction of the telescopically extendable section. Owing to the stop formed by the slipping-off means 62 or the end side of the slipping-off means 62, the ring body 45 remains in its axial position until it has been fully slipped off the inclined tube 60 onto the cable 1a, 1b.

[1084] The cable 1a, 1b can subsequently be removed from the single fitting module 59. For this purpose, it may for example be provided that the support body 61 is formed from multiple shells, in particular two halfshells, which are opened after the fitting of the cable 1a, 1b in order to be able to remove the cable 1a, 1b together with the ring body 45. The principle is shown in FIG. 32.

[1085] It should be mentioned that provision may also be made to apply multiple ring bodies 45 to the same cable 1a, 1b. This may be performed sequentially through multiple use of, for example, one of the single fitting modules 59 described, wherein further fabrication steps optionally follow between the fitting of the individual ring bodies 45, such further fabrication steps for example also including fitting with other plug connector components 26, 44, 45, 46, 47, 56. However, provision may also be made for the cable 1a, 1b to be fitted with multiple ring bodies 45 in a single processing pass, for example by virtue of multiple chambers 51 as illustrated in FIGS. 18 to 22, and optionally also multiple magazines 52, being provided, which are arranged, together with respective slipping-off means 62, in offset fashion along the central axis M of the cable 1a, 1b.

[1086] FIG. 33 shows a single fitting module 59 for assembling an electrical plug connector 12 which has multiple electrical cables 1a, 1b, in order to fit the cables 1a, 1b with a common elastic ring body 56 at a respective defined axial position P. For this purpose, the common elastic ring body 56 has a number of passage bores 57 corresponding to the number of cables 1a, 1b.

[1087] In the exemplary embodiment according to FIG. 33, the fitting of a first electrical cable 1a, 1b and of a second electrical cable 1a, 1b with a common ring body 56, which is in the form of a common line seal 56, is demonstrated merely schematically. The number of cables 1a, 1b and the number of passage bores 57 and also the geometry and design of the common ring body 56 are not to be understood as limiting.

[1088] According to FIG. 33, an inclined tube 60, in particular an inclined tube 60 as described above, is assigned to each cable 1a, 1b.

[1089] The inclined tubes 60 may optionally be fastened to one another, for example by means of a holding frame, for simplified alignment and positioning. A connecting web 68 is illustrated as an example for this.

[1090] In principle, the fitting may also be performed sequentially, following which the cables 1a, 1b are fitted successively with the common dog body 56 using only one inclined tube 60.

[1091] The process of fitting (inserting the inclined tube 60 into the passage bore 57/positioning the respective cable 1a, 1b in the inclined tube 60/slipping-off/etc.) may be performed as has already been described in detail above.

[1092] FIGS. 34 to 37 show a press-in module 69 for assembling an electrical plug connector 12 during various assembly steps. All illustrations are to be understood as examples and as being highly schematic, and are intended merely to impart understanding of the invention.

[1093] FIG. 34 shows a state of the press-in module 69 during the placing-in of prefabricated electrical cables 1b, which are to subsequently be assembled in a housing assembly or a plug connector housing 44 of the plug connector 12. The press-in module 69 will be described purely by way of example on the basis of a plug connector 12 which is able to receive two electrical cables 1b. In principle, the press-in module 69 may also be suitable for use with a plug connector of a different type, in particular for use with a plug connector that has only a single electrical cable 1b.

[1094] The electrical cables 1b illustrated are also to be understood merely as examples. In principle, the invention may be suitable for use with any electrical cable, for example also for use with a multicore cable 1a with multiple inner conductors 2.

[1095] The electrical cables 1b shown by way of example are prefabricated at their respective front cable ends 3, 4 with an inner conductor contact element 8, which is electrically and mechanically connected to an inner conductor 2 of the cable 1b. The inner conductor contact element 8 may for example be pressed together with or welded to, in particular ultrasound-welded to, the inner conductor 2 of the cable 1b. For this purpose, an ultrasound welding device may be provided (not illustrated). As illustrated in the exemplary embodiments, the inner conductor contact element 8 may be received in an insulating housing 70, for example an insulating housing 70 composed of two insulating shells. The cable 1b may furthermore be prefabricated with a support sleeve 15 that has been applied to the cable sheath 5 of the cable 1b and/or to the outer conductor of the cable 1b, in particular to a cable shielding braid 6. A crimp sleeve 71 may have been pushed onto the support sleeve 15 and crimped or pressed together with the support sleeve 15. The cable shielding braid 6 may run between the support sleeve 15 and the crimp sleeve 71, which cable shielding braid has been folded back over the support sleeve 15 prior to the application of the crimp sleeve 71.

[1096] Finally, yet further plug connector components 26, 44, 45, 46, 47, 46, for example the illustrated line seal 45, the cable retainer 46 and the retaining cap 47, may also have been pushed onto the cable sheath 5 of the cable 1b for the subsequent final assembly of the plug connector 12.

[1097] The cables 1b may be fed to the press-in module 69 by a transport device 72 to be described further below, by the feed device 54 and/or by a user. This process is illustrated in FIG. 34.

[1098] In particular during the supply process, it may be provided that a checking device 73 checks correct preprocessing, in particular correct pre-fitting of the cable sheath 5 with the plug connector components 26, 44, 45, 46, 47, 56. The checking device 73 may in particular be designed as an optical checking device 73, for example as a camera or light strip. If the checking device 73 detects incorrect pre-processing of the cable 1b, in particular insufficient pre-fitting of the cable 1b, the assembly process may for example be interrupted and the cable 1b rejected.

[1099] While the cables 1b are being inserted, they may be pushed along an advancing direction, in particular along the feed direction X, into an advancing device 74. The advancing device 74 serves to press the cable end 3, 4 of the cable 1b into a corresponding slot 75 in the plug connector housing 44 of the plug connector 12 and will be described in more detail further below. Instead of the advancing device 74, the feed device 54 may optionally also be used for the pressing-in.

[1100] The cables 1b may preferably be caused to abut against a stop, and aligned in the correct position, at a starting position P.sub.A with the assistance of an alignment aid 76. For this purpose, the alignment aid 76 has, for example, a stop for the crimp sleeve 71.

[1101] The advancing device 74 has a holding device 77 for fixing the cable 1b. In the exemplary embodiment shown in FIGS. 34 to 37, the holding device 77 has two clamping laws that are capable of being fed to the cable sheath 5 of the cable 1b. After the cable 1b has been placed in or supplied, the clamping jaws may be correspondingly closed, or the cable 1b may be fixed by the holding device 77.

[1102] Provision may subsequently be made for the advancing device 74 to feed the cables 1b in the advancing direction or in the feed direction X to the plug connector housing 44 and to press them into the latter.

[1103] In principle, the processing or pressing-in of the cables 1b by the two advancing devices 74 may be performed in parallel or else successively. The cables 1b are preferably pressed in successively in order to be able to better control and monitor the pressing-in process. In principle, a common advancing device 74 or at least a common drive for the advancing devices 74 may accordingly also be provided. In the exemplary embodiment in FIGS. 34 to 37, the advancing device 74 has a rail system in order to move the holding device 77 linearly along the advancing direction or feed direction X. By contrast, in the exemplary embodiment shown in FIGS. 42 to 44, a spindle drive is provided which selectively feeds only one of the two holding devices 77.

[1104] After the cable 1b has been fixed, the plug connector housing 44 may firstly be fixed in an assembly position by means of a fixing device 78 before the cable 1b is pressed in. Two pressing jaws for fixing the plug connector housing 44 are illustrated by way of example.

[1105] The advancing device 74 may subsequently press the cable end 3, 4 of the cable 1b into the corresponding slot 75 in the plug connector housing 44. In this case, the crimp sleeve 71 is preferably pressed into the slot 75, which results in the subsequent holding force of the cable 1b in the plug connector 12.

[1106] A force transducer 79 is provided for detecting the pressing force applied during the pressing-in of the cable 1b. In the exemplary embodiment, the force transducer 79 is part of the advancing device 74 and is merely indicated as a black box in FIG. 34. The advancing device 74 presses the cable end 3, 4 of the cable 1b into the plug connector housing 44 until the inner conductor contact element 8 has reached a setpoint position P.sub.S within the plug connector housing 44. An optical sensor unit 80 detects the actual position P.sub.1 of the inner conductor contact element 8 within the plug connector housing 44 during the pressing-in of the cable 1b.

[1107] A control unit 10 of the press-in module 69 (likewise merely indicated as a black box in FIG. 34) may be provided for monitoring the pressing-in process, in particular for evaluating the detected actual position P.sub.1 and the detected pressing force in the context of quality assurance. The control unit 10 is able to evaluate the pressing force detected by the force transducer 79 during the pressing-in and to compare it with a specification for the pressing force. If the pressing force does not correspond to the specification, the plug connector 12 may for example be correspondingly marked, and rejected if necessary.

[1108] FIGS. 38 to 41 show the pressing of the cable 1b into the plug connector housing 44 in a side view, wherein the plug connector housing 44 is illustrated in section and in highly simplified form.

[1109] The plug connector housing 44 may have a spring-loaded latching means 81 in order to fix the inner conductor contact element 8. In order to simplify the assembly of the cable 1b in the plug connector 12, a preloading device 82 may be provided in order to initially mechanically preload the latching means 81 within the plug connector housing 44 orthogonally with respect to the advancing direction or with respect to the feed direction X. For this purpose, the preloading device 82 may for example have an extendable telescopic ram 83 which preloads the latching means 81 out of the displacement path of the inner conductor contact element 8 counter to a spring force. In order to subsequently open up the displacement path for the inner conductor contact element 8 again, the preloading device 82 can be removed from the displacement path when contact with the inner conductor contact element 8 occurs or when contact with the inner conductor contact element 8 is impending. By way of example, a button element 84 is illustrated, which can be touched by the inner conductor contact element 8 and thereby triggers the retraction, for example also a mechanical snapping-in movement, of the telescopic ram 83 (cf. FIGS. 39 and 40). The cable end 3, 4 of the cable 1b can then be pressed further into the plug connector housing 44 until the inner conductor contact element 8 has reached its setpoint position P.sub.S in the plug connector housing 44 (cf. FIG. 41).

[1110] FIGS. 42 to 44 show a preferred exemplary embodiment of the press-in module 69. FIG. 42 shows the state during the placement of a first cable 1b into the press-in module 69. FIG. 43 shows a state of the press-in module 69 in which the cable 1b has been aligned in the correct position in the starting position P.sub.A by means of the alignment aid 76. In FIG. 44, the cable 1b has been fixed by a single clamping jaw of the holding device 77 by virtue of the cable 1b being pressed by the clamping jaw against a support. In FIG. 44, the plug connector housing 44 is furthermore fixed, for the subsequent pressing-in operation, by a fixing device 78 with a single pressing jaw in the form of a plate having a negative form of the plug connector housing 44.

[1111] FIG. 45 shows the exemplary, schematically illustrated plug connector 12 during its final assembly process (cf. also FIG. 76). In the course of the final assembly process after the cables 1b have been pressed in, provision may be made to assemble the further plug connector components 45, 46, 47. For this purpose, the line seal 45 may firstly be pushed into the respective slot 75 of the plug connector housing 44 and fixed by the cable retainer 46. The retaining cap 47 may then be applied to the slot 75 from the outside and fixed.

[1112] FIGS. 46 to 52 show an advantageous feed device 54 for assembling the electrical plug connector 12 according to an exemplary embodiment during various method steps.

[1113] The feed device 54 has a first transport module 85 in order to feed a cable section to be processed, in particular a cable end 3, 4 of at least one electrical cable 1a, 1b, along a feed direction X (cf. FIG. 46) into a processing module for processing the cable 1a, 1b in the course of the plug connector assembly process, or in order to move said cable section out of the processing module counter to the feed direction X. By way of example, the above-described single fitting module 59 is illustrated as a black box as a processing module; it is however possible in principle for the feed device 54 to be used to feed the cable end 3, 4 into any processing module. The feed device 54 may also be present in a plurality for this purpose.

[1114] The feed device 54 furthermore has a second transport module 86, which is preferably independent of the first transport module 35 and which is arranged at a position spaced apart from the first transport module 85 in the feed direction X. The second transport module 86 is also able to transport the cable end 3, 4 along or counter to the feed direction X.

[1115] The first transport module 95 has transport units 87 which can be fed to the cable 1a, 1b, which transport units are repositionable such that plug connector components 26, 44, 45, 46, 47 applied to the cable end 3, 4 can pass through the first transport module 85, while the second transport module 86 is transporting the cable 1a, 1b. The principle will be illustrated in more detail below.

[1116] FIG. 46 shows the feed device 54 while the electrical cable 1a, 1b is being placed in. The cable 1a, 1b may be placed (or inserted in some other way) into the second transport module 86, the clamping bodies 88 of which are for this purpose initially opened or sufficiently spaced apart from the central axis M of the cable 1a, 1b.

[1117] The cable 1a, 1b may optionally be placed on a first guide device 89 which is arranged upstream of the second transport module in the feed direction X and which serves for guiding the cable 1a, 1b.

[1118] After the cable 1a, 1b has been placed into the second transport module 86, provision may be made for the second transport module 86 to feed its clamping bodies 88 in the direction of the central axis M of the cable 1a, 1b (cf. arrows in FIG. 46). In the exemplary embodiment, the clamping bodies are for example in the form of roller bodies 88, which are able to guide the cable 1a, 1b tangentially between them.

[1119] For safety reasons, it may initially be provided that the second transport module 86 fixes the cable 1a, 1b by means of the clamping bodies or roller bodies 88 only with a force that does not pose a danger to the user, for example using one or more springs. It may be provided that the second transport module 86 increases the force of the clamping bodies or rolling bodies 88 against the cable 1a, 1b, for example using a pneumatic or hydraulic unit, only when the user has removed their hand or a tool from a defined danger area.

[1120] FIG. 47 illustrates how the second transport module 86 transports the cable 1a, 1b in the direction of the first transport module 85. For this purpose, the second transport module 86 has a linear drive in order to transport the cable 1a, 1b along or counter to the feed direction X. For this purpose, a guide rail 90 is provided, along which the second transport module 86 is able to move the clamping bodies or roller bodies 88 with the cables 1a, 1b held therein linearly in a specified range in or counter to the feed direction X. For the feed of the cable 1a, 1b by the second transport module 86, the roller bodies 88 are blocked by a brake unit. The brake unit is shown in the figures only schematically in the form of lateral brake shoes. In principle, however, the brake unit may be implemented in any desired form, and may in particular also act directly on the axis of the roller bodies 88.

[1121] FIG. 48 shows the transfer of the cable 1a, 1b to the first transport module 45 for the onward transport of the cable 1a, 1b by the first transport module 45. For this purpose, the second transport module 46 has reached its end stop (this is however not imperatively the case). The first transport module 45 has transport units 87 which are capable of being fed in the direction of the central axis M of the cable 1a, 1b and which, in the exemplary embodiment, are designed as transport rollers 87 which are able to guide the cable 1a, 1b tangentially between them. In the method step in FIG. 48, the transport units or the transport rotors 87 are fed or closed in the direction of the central axis M of the cable 1a, 1b (cf. arrows in FIG. 48).

[1122] FIG. 49 illustrates how the first transport module 45 feeds the cable 1a, 1b into the single fitting module 59 through the driving of the transport rollers 87. In order to enable the first transport module 85 to feed the cable 1a, 1b, it is provided that the roller bodies 88 of the second transport module 86 are released from the previously blocked state, such that they can rotate freely, by the brake unit. The roller bodies 88 of the second transport module 86 are thus able to roll freely on the cable sheath 5 of the cable 1a, 1b while the first transport module 85 feeds the cable 1a, 1b into the single fitting module 59. In accordance with this principle, the transport of the cable 1a, 1b can be imparted selectively by the first transport module 85 or by the second transport module 86. The second transport module 86 is preferably stationary in the feed direction X while the first transport module 86 feeds the cable 1a, 1b into the single fitting module 59.

[1123] As already mentioned, the processing module may be designed as any processing module in the context of a cable fabrication or plug connector assembly process. However, the processing module is preferably designed as a fitting module, in particular as a single fitting module 59, in order to fit the cable end 3, 4 with at least one plug connector component 26, 44, 45, 46, 47 starting from a front, free end for the plug connector assembly process. By way of example, the single fitting module 59 in FIGS. 46 to 52 is provided as a single fitting module 59 in order to fit the cable 1a, 1b with a line seal 45.

[1124] In order to advantageously support the cable 1a, 1b, a second guide device 91 may optionally be provided between the first transport module 85 and the second transport module 86.

[1125] By virtue of the fact that the first transport module 85 is arranged closer to the processing module or to the single fitting module 59 in the feed direction X than the second transport module 86, preferably directly adjacent to the processing module or to the single fitting module 59, the first transport module 85 can impart a relatively high force and a high degree of precision when inserting the cable 1a, 1b. Furthermore, kinking or bending of the cable 1a, 1b during the insertion into the line seal 45 (or the other plug connector component 26, 44, 46, 47) is avoided.

[1126] After the processing, for example fitting of the cable end 3, 4, the cable 1a, 1b is preferably removed again from the processing module or from the single fitting module 59. For this purpose, the first transport module 85 may move the cable 1a, 1b out of the single fitting module 59 counter to the feed direction X, as illustrated in FIG. 50. However, this can lead to a collision of the plug connector components 26, 44, 45, 46, 47 (or other components) with the transport rollers 87, which must be avoided.

[1127] As illustrated in FIG. 51, it may be provided that the transport units 87 of the first transport module 85 are opened in order to allow the plug connector components 26, 44, 45, 46, 47 (for example the illustrated line seal 45) applied to the cable sheath 5 of the cable 1a, 1b to pass through the first transport module 85 while the second transport module 86 transports the cable 1a, 1b onward. For this purpose, the clamping bodies 88 of the second transport module 86 may be blocked again by means of the brake unit. In this way, the fitted cable 1a, 1b can be moved through the first transport module 85, for example until it reaches the end position shown in FIG. 52, in which the clamping bodies 88 of the second transport module 86 may optionally be opened again.

[1128] Optionally, a checking device 73 may be provided and configured to check for correct processing of the cable 1a, 1b during the feed of the cable end 3, 4 into the processing module or into the single fitting module 59 or while the cable end 3, 4 is being moved out of the single fitting module 59, or to thoroughly check the cable 1a, 1b for processing defects or for material defects. By way of example, two cameras 73 are shown.

[1129] FIGS. 53 to 55 show, by way of example, various roller bodies 88 that can be advantageously used in the second transport module 86. The cable 1a, 1b is shown merely in simplified form in FIGS. 53 to 55

[1130] As illustrated in the Figures, the roller bodies 88 may, alone the circumference, comprise notches 92 or even a negative form of the cable sheath 5 in order to improve the guidance of the cable 1a, 1b.

[1131] The feed device 54 is also suitable for assembling an electrical plug connector 12 which has multiple electrical cables 1a, 1b. In this case, it may be necessary for the transport modules 85, 86 to feed multiple cables 1a, 1b, for example two cables 1a, 1b.

[1132] FIGS. 54 and 55 show, by way of example on the basis of the second transport module 86, possible configurations of the roller bodies 88 if more than one cable 1a, 1b is to be transported.

[1133] In FIG. 54, the two roller bodies 88 have a number of notches 92 corresponding to the number of cables 1a, 1b, which notches are axially offset along the central axis of the roller bodies 88 in order to specify a defined spacing between the two cables 1a, 1b.

[1134] By contrast, in FIG. 55, two roller bodies 88 are used per cable 1a, 1b. Given a suitable actuator system, it is thus also possible, for example, for the cables 1a, 1b to be transported independently of one another.

[1135] FIG. 56 shows a documentation module 93 for the plug connector assembly process according to the invention.

[1136] In the course of the plug connector assembly process, various pieces of information may advantageously be recorded in documentation 96 of the processing of the cable 1a, 1b. For example, information from a check for an absence of damage of a cable component of the cable 1a, 1b (for example of the cable sheath 5, of the cable shielding braid 6 or of the insulation 2.2) may be taken into consideration. Furthermore, a check for an absence of damage of a plug connector component 26, 44, 45, 46, 47, 56 of the plug connector 12 to be assembled on the cable 1a, 1b may be performed, wherein the results of the check are finally recorded in the documentation 96. A check for radial alignment of plug connector components 26, 44, 45, 46, 47, 56 may also be performed, the results of which are in turn recorded in the documentation 96. In particular, the result of a check for the presence of certain plug connector components 26, 44, 45, 46, 47, 56 after the fitting of the cable sheath 5, for example of the line seal 45, may also be advantageous in the context of the documentation 96.

[1137] In principle, any process parameters of the processing processes may be recorded in the documentation 96.

[1138] In the context of the transport device 72, a workpiece carrier system 94 may be provided which has a workplace carrier 11 on which the electrical cable 1a, 1b is fastened. The electrical cable 1a, 1b may thus be assigned to the workplace carrier 11 during the processing thereof throughout the entire plug connector assembly process or during a section of the plug connector assembly process.

[1139] The workpiece carrier 11 has clamping units 95 in order to fix the first cable end 3 and/or the second cable end 4 of the cable 1a, 1b, in the exemplary embodiment both cable ends 3, 4. In the exemplary embodiment, the cable 1a, 1b is clamped into the workpiece carrier 11 such that a U-shaped profile is formed between the two cable ends 3, 4. In principle, a profile deviating from this may also be provided, for example a helical winding in the case of a relatively long cable 1a, 1b. It may also be provided that only one of the two cable ends 3, 4 is received in the workpiece carrier 11 (cf. for example FIG. 71). The actual configuration of the workplace carrier 11 and the type of fastening of the cable 1a, 1b on the workpiece carrier 11 are not of importance in the context of the invention.

[1140] In order to transport the cable 1a, 1b for the processing thereof, the workpiece carrier 11 is assembled, for example, on a transport device 72 in the form of a conveyor belt. In principle, however, the cable 1a, 1b may be transported in any desired manner, as will be discussed further below.

[1141] As already mentioned in connection with FIG. 6, it may be provided that the cable 1a, 1b and/or the workplace carrier 11 has an information carrier for identification purposes. As an alternative or in addition to an information carrier on the cable 1a, 1b or on the workpiece carrier 11, it may also be provided that the cable 1a, 1b is made identifiable by means of at least one sheath clamp 48a, 48b, 48c, 48d fastened to the cable sheath 5. In FIG. 56, an exemplary sheath clamp 48a is fastened to both cable ends 3, 4 of the cable 1a, 1b. The sheath clamp 48a may likewise be provided with any desired information carrier. An optical marking 21 (barcode) on the sheath clamp 48a of the first cable end 3 and a transponder 23 (RFID) on the sheath clamp 48a of the second cable end 4 are illustrated by way of example. In principle, different types of sheath clamps 48a, 48b, 48c, 48d may be provided, as already stated.

[1142] In the context of the documentation module 93, it may be provided that documentation 96 of the plug connector assembly process or of the processing of the cable la, lb is compiled for at least one, processing operation and assigned to the cable 1a, 1b.

[1143] For this purpose, it is for example possible for a unique identifier for the cable 1a, 1b to be imprinted in the information carrier and/or for a unique identifier already imprinted on the information carrier to be assigned to the cable 1a 1b temporarily for the fabrication thereof.

[1144] The identifier may for example be a binary, decimal or hexadecimal numerical value or a numerical sequence. The identifier may for example be encoded or imprinted in the barcode or some other code. The identifier may also be imprinted or stored in an electronic component, for example a memory module, for example in the RFID transponder 23.

[1145] For example, it may also be provided that different workpiece carriers 11 already have a respective information carrier with a respective unique identifier. Through the assignment of the cable 1a, 1b to the work-piece carrier 11 during the fabrication process or at least during a sub-process of the fabrication process, the documentation 96 can ultimately be assigned. It may however also be provided, for example, that the information carrier is provided in targeted fashion with an identifier for the identification of the cable 1a, 1b for the fabrication operation to be documented.

[1146] It may be provided that the documentation 96 is at least partially imprinted in the information carrier. This may be advantageous in particular if the information carrier is an electronic information carrier 23 on which sufficient storage space is available (indicated in FIG. 56). It is however also possible, for example, for a continuous numerical sequence or a similar code to be provided in order to record the documentation 96 continuously in the course of the plug connector assembly process, for example in optical form on the cable 1a, 1b.

[1147] For example, a read/write unit 22 and/or a scanner for reading out a barcode (or some other code) and/or a laser 20 or a printer may be provided in order to augment the documentation 96 or to evaluate it for the cable processing operation.

[1148] Preferably, however, a global database 97 may be used in which documentation 96 compiled in the course of the fabrication production line can be assigned to individual cables 1a, 1b, preferably on the basis of the respective unique identifier. The addressing in the database 97 may thus be implemented in a manner dependent on the identifier of the respective cable 1a, 1b.

[1149] The documentation module 93 may have a control unit 10 in order to carry out the described documentation method. It is however also possible, for example, for a global control device 96 (cf. FIG. 71) or some other control unit 10 to be provided for managing the documentation. The control unit 10 may for example be communicatively connected to the devices for imprinting and/or reading out and/or modifying the information carrier (indicated with regard to the read/write unit 22) and may furthermore be communicatively connected to the database 97.

[1150] For example, information relating to a successful processing process, an incorrect processing process, a failed processing process and/or at least one process parameter of the processing process may be included in the documentation 96. The documentation 96 may be used in the context of quality management. In the context of the quality management, provision may for example be made to sort the cable 1a, 1b, or to approve it for post-processing, in a manner dependent on the information contained in the documentation 96. In particular, removal of an incorrectly processed cable 1a, 1b in the course of the cable fabrication process may be provided in the context of the quality management.

[1151] The information for the documentation 96 may be recorded by the control unit 10 using a communication interface, for example.

[1152] FIGS. 57 to 59 illustrate, by way of example, three successive assembly steps in the context of an assembly module 29 for a plug connector assembly process according to the invention. The principle is illustrated by way of example together with a two-core, shielded electrical cable 1a. In principle, however, the assembly module 29 is suitable for use with any cables 1a, 1b, in particular with any number of inner conductors 2. The illustrations, in particular the dimensions and geometrical designs, are likewise to be understood merely as examples.

[1153] The electrical cable 1a, which is being processed by way of example starting from FIG. 57, has already been partially prefabricated. In the course of the previous processing, the inner conductors 2 have been exposed at their ends. The inner conductor contact elements 8 have subsequently been fastened, in particular crimped, to the respective inner conductors 2. Furthermore, the cable shielding braid 6 has been folded back over the cable sheath 5, preferably over the support sleeve 15, and fixed with the fabric tape 9. In addition, further plug connector components 26, 44, 45, 46, 47 of the plug connector 12 (in the exemplary embodiment, only the shielding sleeve 26 is shown by way of example) have already been pushed onto the electrical cable 1a in order that these can be assembled in subsequent steps starting from the cable side.

[1154] In the method step illustrated in FIG. 57, the inner conductor contact elements 8 are firstly assembled in a respective receptacle 99 of the contact part carrier 13. The contact part carrier 13 is illustrated in section in FIGS. 57 to 59 for better clarity.

[1155] Before the inner conductor contact elements 8 are pushed into the respective receptacles 99, the spacing of the inner conductor contact elements 8 or of the inner conductors 2 of the electrical cable 1a to one another may be adapted to the spacing of the receptacles 99 of the contact part carrier 13 (so-called pitch change). To assemble the contact part carrier 13, the assembly module 29, to be described in more detail below, may optionally have an assembly device 100. The illustration shows, by way of example, two clamping jaws 102, which are guided on respective rails 101 and are capable of being fed to the contact part carrier 13, for pushing the contact part carrier 13 over the inner conductor contact elements 8 along the central axis M of the electrical cable 1a. As an alternative or in addition, the electrical cable in may also be moved. Instead of the assembly device 100, the abovementioned feed device 54 may also be used to assemble the inner conductor contact elements 8 in the contact part carrier 13.

[1156] For advantageous assembly of the contact part carrier 13 on the inner conductor contact elements 8, it is for example also possible for centring pins to be provided, which are led through a front opening, which faces towards what will later be a mating plug connector, of the contact part carrier 13 or through the receptacles 99 and which serve as a threading-in aid for the generally hollow cylindrical inner conductor contact elements 8 (not illustrated in the exemplary embodiment).

[1157] FIG. 58 shows a method step in the course of the plug connector assembly process in which an axial actual position P.sub.IST of at least one inner conductor contact element 8, which is fastened to an inner conductor 2 of the electrical cable 1a, within the contact part carrier 13 relative to an intended axial end position P.sub.END is checked by a sensor module 103. The sensor module 103 may be part of the assembly module 29. The sensor module 103 may however also be independent of the assembly module 29. At the time of assembly shown in FIG. 58, the inner conductor contact elements 8 have already been introduced into the contact part carrier 13. By way of example, the inner conductor contact element 8 illustrated at the top in FIG. 58 is illustrated in its end position P.sub.END, and the inner conductor contact element 8 illustrated at the bottom in FIG. 58 has not yet been pushed sufficiently into the receptacle 99 of the contact part carrier 13.

[1158] In the exemplary embodiment, the axial end position P.sub.END corresponds to the position of the front, free end of the inner conductor contact element 8 when the inner conductor contact element 8 has been fully latched with a primary latching means 104.

[1159] In the case of the inner conductor contact element 8 situated in its axial end position P.sub.END, the primary latching means 104, which is indicated purely by way of example, of the contact part carrier 13 has been latched with a complementary groove of the inner conductor contact element 8. In principle, any latching connection between the primary latching 104 and the inner conductor contact elements 8 may be provided.

[1160] The sensor module 103 is configured to detect the axial actual position P.sub.IST of the at least one inner conductor contact element 8 within the contact part carrier 13 relative to the intended axial end position P.sub.END. In FIG. 58, various sensors of the sensor module 103 are illustrated in combination by way of example.

[1161] For example, it may be provided that the sensor module 103 is configured to detect the position of a front, free end of the at least one inner conductor contact element 8 within the contact part carrier 13.

[1162] The sensor module 103 may for example have a tactile sensor, preferably a measuring probe 105 or a force transducer, which is insertable through the front opening or a receptacle 99 of the contact part carrier 13. The illustration shows, by way of example, a measuring probe 105 for detecting the actual position P.sub.IST of a front end face of the upper inner conductor contact element 8. Instead of the measuring probe 105, it is however similarly also possible for a force transducer to be provided in order to check the actual position P.sub.IST by way a compressive or tensile check, in particular in order to determine whether the at least one inner conductor contact element 8 has been latched by the primary latching means 104. In this way, although it is generally not possible to detect the exact relative position of the inner conductor contact element 8, it is possible to determine whether the actual position P.sub.IST, corresponds to the intended axial end position P.sub.END.

[1163] For contactless detection of the actual position P.sub.IST of the inner conductor contact element 8 within the contact part carrier 13, an optical sensor may for example also be provided. A laser system 106 for distance measurement is illustrated by way of example in FIG. 58. Even a camera may however be sufficient. Furthermore, for contactless detection of the actual position P.sub.IST, it is for example also possible for an inductive sensor or capacitive sensor to be provided, which preferably detects the actual position P.sub.IST of the inner conductor contact element 8 through the contact part carrier 13.

[1164] If the sensor module 103 has detected correspondence of the actual position with the intended end position P.sub.END, provision may be made to continue the plug connector assembly process. Alternatively, a repair or a rejection of the electrical cable 1a may be provided.

[1165] After correspondence between actual position P.sub.IST and end position P.sub.END has been determined, it may be provided that a secondary securing means 107 is actuated in order to secure the primary latching means 104. A secondary securing means 107 may be designed as a blocking element which, in its securing state, is situated in the displacement path of the primary latch 104 and can prevent an opening of the primary latching means 104 in positively locking fashion. An exemplary secondary securing means 107 or an exemplary blocking element is illustrated in FIG. 59.

[1166] To actuate the secondary securing means 107, the assembly module 29 may optionally have an actuation means 108 (cf. FIG. 60), which may be connected to the sensor module 103 via a signal path and may be configured to actuate the secondary securing means 107 when the actuation means 108 receives an actuation signal from the sensor module 103. The actuation means 108 may for example, as illustrated in FIG. 60, be linearly adjustable in order for the actuation means 108 to be pushed into the contact part carrier 13. The sensor module 103 of FIG. 60 is for example designed to detect the axial actual position P.sub.IST of both inner conductor contact elements 8 separately by means of two measuring probes 105.

[1167] FIG. 61 illustrates a quality monitoring module 109 for the quality monitoring of the plug connector assembly process according to the invention. Using the quality monitoring module 109 illustrated, the state of at least one of the two cable ends 3, 4 of the cable 1a, 1b can be detected before and/or after at least one processing operation.

[1168] It is provided here that the line of sight S of a first optical sensor 110 is aligned with the cable end 3, 4, wherein a first lighting unit 111 is arranged behind the cable end 3, 4 along the line of sight S of the first sensor 110 in order to generate transmitted light or back light for the optical detection of the cable end 3, 4.

[1169] Furthermore, the line of sight S of a second optical sensor 112 is likewise aligned with the cable end 3, 4, wherein a second lighting unit 113 is arranged in front of the cable end 3, 4 along the line of sight S of the second sensor 112 in order to generate incident light for the optical detection of the cable end 3, 4. The first sensor 110 and the second sensor 112 are each designed as a camera with a respective lens.

[1170] To illuminate the cable end 3, 4, the lighting units 111, 113 each have illuminants (not illustrated in any more detail). The illuminants may for example be arranged in a row arrangement and/or in a column arrangement. In principle, it is also possible for only a single illuminant to be provided in order to emit light from the respective lighting unit 111, 113.

[1171] So as not to block the view from the second sensor 112 to the cable end 3, 4, the second lighting unit 113 has a central recess 114.

[1172] The first lighting unit 111 and the second lighting unit 113 are arranged coaxially with the lines of sight S of the optical sensors 110, 112 respectively. In principle, however, an offset arrangement may also be provided.

[1173] The second sensor 112 is arranged so as to be offset with respect to the first sensor 110 by a defined angle α. In principle, the angle α may assume any value. Preferably, an offset of 10° to 170°, particularly preferably of 45° to 135°, more preferably of 80° to 100° and very particularly preferably of 90°, may be provided.

[1174] The lines of sight S of the sensors 110, 112 are preferably aligned orthogonally with respect to the central axis M of the cable 1a, 1b. However, a tilted alignment may also be provided.

[1175] It may be provided that the first lighting unit 111 emits light in a first light colour and/or in a first light polarization which is predominantly perceptible, or is exclusively perceptible, by the first sensor 110 and is predominantly not perceptible, or is not perceptible, by the second sensor 112. Correspondingly, the second lighting unit 113 may be designed to emit light in a second light colour and/or in a second light polarization which is predominantly perceptible, or is exclusively perceptible, by the second sensor 112 and is predominantly not perceptible, or is not perceptible, by the first sensor 110.

[1176] It can be ensured in this way that a measurement by means of the first sensor 110 does not adversely affect a measurement by the second sensor 112, and vice versa. For example, corresponding optical filters 115 may be provided in order to filter out the light colour and/or light polarization of the lighting unit 111, 113 assigned to the respective other sensor.

[1177] In principle, it is also possible for the sensors 110, 112 to perform time-shifted measurements, wherein the first lighting unit 111 illuminates the cable end 3, 4 preferably only in time intervals in which the first sensor 110 is performing the measurement, and wherein the second lighting unit 113 illuminates the cable end 3, 4 preferably only in time intervals in which the second sensor 112 is performing the measurement.

[1178] A control unit 10 or the control device 98 can control the measurements or the sensors 110, 112 and the lighting units 111, 113 accordingly. The control unit 10 illustrated by way of example in FIG. 61 may in principle also be used to evaluate the state of the cable end 3, 4 on the basis of the data detected by means of the quality monitoring module 109.

[1179] Provision may furthermore be made to rotate the sensors 110, 112 radially around the central axis M of the cable 1a, 1b, and/or to rotate the cable 1a, 1b about its central axis M, while the sensors 110, 112 capture individual images and/or video information. The lighting units 111, 113 may preferably be rotated synchronously with the sensors 110, 112 assigned thereto, for example if said lighting units are arranged on a common frame with their assigned sensor 110, 112 and/or if the electrical cable 1a, 1b is rotated. To impart the rotational movement, a rotation device 116 may be provided, which is indicated by way of example in FIG. 61 as a black box. The rotation device 116 may preferably have a servo motor or be designed as a servo motor.

[1180] The following FIGS. 62 to 70 show advantageous embodiments of a cleaning module 117 for cleaning the cable 1a, 1b, in particular the cable end 3, 4 of the cable 1a, 1b, in the course of a plug connector assembly process according to the invention. In principle, it may be provided that, after at least one mechanical processing operation of the cable end 3, 4, a cleaning process is executed, in which particles 118 adhering to the cable end 3, 4 are removed.

[1181] The particles 118 may also be examined by a waste and/or particle monitoring system in order to be able to indirectly detect the processing success of a processing operation through a comparison of the waste or particles 118 formed in the course of the processing process with an expected amount of waste or particles and/or with an expected type of waste or particles.

[1182] For example, in the context of the cleaning module 117, provision may be made for the particles to be blown off, as indicated by way of example in FIGS. 62 to 65 and 70.

[1183] FIG. 62 illustrates, by way of example, the use of a ring nozzle 119 for blowing the particles 118 off the electrical cable 1a, 1b. The ring nozzle 119 has a channel for the supply of compressed air and multiple, for example four, individual nozzles 120 for the discharge of the compressed air. In principle, a ring nozzle 119 with only one, two, three or even more than four individual nozzles 120 may also be provided. It may also be provided that the ring nozzle 119 has a radially partially or fully encircling ring-shaped gap for the discharge of the compressed air.

[1184] Provision may be made for the electrical cable 1a, 1b and/or the ring nozzle 119 to be moved axially relative to one another, and/or rotated, for the processing or for the blowing-off operation.

[1185] FIG. 63 illustrates the use of a ring nozzle 119 in a side view, wherein the ring nozzle 119 has been enhanced to include an ionizer 121 in order to supply ionized air to the cable end 3, 4. In this way, the electrostatic attraction of the particles 118 can be reduced and the particles 118 can be blown off more easily. The ionizer 121 may be arranged upstream of, downstream of or adjacent to the ring nozzle 119.

[1186] A suction-extraction device 122 is additionally illustrated in FIG. 63, wherein the particles 118 are blown off by the ring nozzle 119 in targeted fashion onto the suction-extraction device 122 in order to collect the blown-off particles 118. As an alternative or in addition, provision may also be made, in the context of the blowing-off operation, to blow the particles 118 off in targeted fashion onto a collecting container and/or a filter unit.

[1187] FIG. 64 shows the use of a cleaning module 117 with a flat nozzle 123 in order to be able to blow off particles 118 in an even more targeted manner. Provision may be made here to rotate the nozzle 123 about the cable 1a 1b or to rotate the cable 1a, 1b along its central axis M.

[1188] In order to further improve the processing success, in particular in the course of the blowing-off operation, it may be provided that the air flow generated in the course of the cleaning process is pulse-controlled. The principle is likewise illustrated by way of example in FIG. 64. For example, the control unit 10 of the cleaning module 117 can correspondingly control a solenoid valve 124 of the nozzle 123 via a signal connection, as indicated. Owing to the pulsed air flow, the particles 118 can detach more easily from the electrical cable 1a, 1b, for example owing to turbulence.

[1189] It may also provided that the cleaning process comprises a compressed air blasting process, in particular a dry ice blasting process or a CO.sub.2 blasting process. For this purpose, a nozzle 123 of the type shown in FIG. 64 may for example be provided.

[1190] FIG. 65 shows a further exemplary cleaning module 117. The cleaning module 117 illustrated in FIG. 65 shows a combination of a nozzle 123 for blowing the particles 118 off and a suction-extraction device 122 for the extraction of the particles 118 by suction. The suction-extraction device 122 is arranged opposite the nozzle 123, wherein the cable 1a, 1b is arranged between the nozzle 123 and the suction-extraction device 122. In this variant, too, provision may be made inter alia to rotate the electrical cable 1a, 1b and/or the cleaning module 117 in order to remove the particles 118 from the electrical cable la, 1 b over the full circumference.

[1191] FIG. 66 shows a cleaning module 117 in which the particles 118 are brushed off the electrical cable 1a, 1b. The cleaning module 117 has four driven brushes 125 which are distributed along the circumference of the electrical cable 1a, 1b. In principle, however, the cleaning module 117 may also have only one brush 125, two brushes 125, three brushes 125 or even more than four brushes 125. The cable 1a, 1b or the brushes 125 may optionally be rotatable radially about the central axis M of the cable 1a, 1b during the processing operation.

[1192] FIG. 67 illustrates a further variant for the brushing-off operation. FIG. 67 shows a spiral brush 126 through which the electrical cable 1a, 1b can be led axially in order to be brushed. The spiral brush 126 and/or the cable 1a, 1b may optionally also be rotated.

[1193] As an alternative or in addition to brushing-off operation, the particles 118 may also be wiped off, for example by means of a cloth (not illustrated in the figures). Furthermore, provision may be made for the particles 118 to be washed off, in particular with a non-corrosive liquid. Furthermore, provision may be made for one or more magnets to be used to remove particles 118 on which a magnet can impart a magnetic action.

[1194] FIG. 68 shows a further cleaning module 117 in which the cleaning process is performed by means of an adhesion process, in which the particles 118 are removed by means of a foil 127 or an adhesive strip. For this purpose, a corresponding foil 127 may be fed to the electrical cable 1a, 1b for example by means of one or more half-shells 128. In the exemplary embodiment, two half-shells 128 are capable of being fed radially to the electrical cable 1a, 1b. In FIG. 68, the upper half-shell 128 has been fed to the electrical cable 1a, 1b and the lower half-shell 128 has not yet been fed to the electrical cable 1a, 1b. During the feed movement, the foil 127 may come to lie against the electrical cable 1a, 1b. Following the processing, the foil 127 may be exchanged or cleaned. It may be advantageous for the half-shells 128 to be fed successively or to be fed such that the foils 127 do not make contact with one another in the middle, because they may otherwise adhere to one another.

[1195] FIG. 69 shows a cleaning module 117 in which the cable end 3, 4 is subjected to defined vibrations during the cleaning process in order to loosen the particles 118. For this purpose, a vibrator 129 is provided, which is fastened to an electrical cable 1a, 1b by means of a gripping device.

[1196] As already mentioned in the introduction, the individual variants may be combined with one another in virtually any desired manner.

[1197] FIG. 70 shows an example of a cleaning module 117 in which blowing off by means of an individual nozzle 123 and a suction-extraction device 122 have advantageously been combined. The electrical cable 1a, 1b be inserted axially into a corresponding receptacle 130 of the cleaning module 117 (and/or the cleaning module 117 is pushed over the cable 1a, 1b). Here, the particles 118 can be blown off by the nozzle 123 in the direction of the suction-extraction device 122. The electrical cable 1a, 1b can then be led out of the receptacle 130 again. During the processing, the cable 1a, 1b and/or the cleaning module 117 may be rotated.

[1198] The cleaning module 117 shown in FIG. 70 may advantageously be combined with or supplemented by further variants mentioned above. In particular, a vibrator 129 and/or an ionizer 121 may likewise be provided. It is for example also possible for one or more brushes 125 to be positioned upstream of the receptacle 130.

[1199] FIGS. 71 to 73 show individual details of an apparatus 131 for assembling an electrical plug connector 12 on a first cable end 3 and/or on a second cable end 4 according to a first embodiment, in which a multicore plug connector 12 is assembled on a multicore cable 1a. FIGS. 74 to 76 show individual details of a corresponding apparatus 131 according to a second embodiment of the invention, in which a single-core plug connector 12 is assembled on a single-core cable 1b.

[1200] The apparatus 131 comprises multiple mutually independent processing modules for assembling the electrical plug connector 12, some of which have already been described above. In principle, the processing modules may be any processing modules for the fabrication of electrical cables 1a, 1b or for the assembly of plug connectors. Only two particularly advantageous combinations of processing modules will be presented below. The arrangement of the processing modules may therefore also differ if necessary. Furthermore, further processing modules may be added or existing processing modules may be divided up or combined.

[1201] The processing modules are preferably of modular construction and are for example operable autonomously. For example, each of the processing modules may have a dedicated control unit 10 in order to autonomously or independently control and/or monitor the processing of the cable 1a, 1b.

[1202] The apparatus 131 may preferably have a control device 96 which is able to globally control and/or monitor the entire plug connector assembly process. The control device 96 may be communicatively connected to the individual control units 10 (merely indicated by way of example in FIG. 71).

[1203] The processing modules may preferably be clocked in a synchronized manner in order to provide the most efficient possible production line for the plug connector assembly process.

[1204] The processing modules may be arranged adjacent to one another along a transport direction T. A transport device 72 for transporting the cable 1a, 1b may specify the transport direction T along which the cables 1a, 1b are transported between the processing modules.

[1205] The transport device 72 may in particular have a workpiece carrier system 94 with at least one workpiece carrier 11 for transporting the cable 1a, 1b. The workpiece carrier system 94 is configured in FIGS. 71 to 76 in the form of a conveyor belt.

[1206] The transport device 72 may also have a gripper device 132 (cf. FIG. 72) with at least one gripper, in particular in order to transport the cable 1a, 1b individually or together with the workpiece carrier 11 between individual conveyor belts of the workpiece carrier system 94.

[1207] Furthermore, the transport device 72 may also have a roller conveyor 133 (cf. FIG. 71)), for example in order to assist manual onward transport of the cable 1a, 1b and/or of the workpiece carrier 11. For example, a production technician can thus also transport the cable 1a, 1b at least between individual modules of the processing modules.

[1208] With regard to the assembly of a two-core plug connector 12, an arrangement of processing modules in accordance with the following sequence has proven to be particularly suitable. The processing modules mentioned below may in particular have features of the processing modules described above.

[1209] An alignment module 134 for aligning the electrical cable 1a may for example be provided as first processing module within the apparatus 131. The alignment module 134 may be configured to, for the processing of the multicore cable 1a, initially determine the actual alignment A.sub.IST and the setpoint alignment A.sub.SOLL of the inner conductors 2 of the first cable end 3. In order to then adapt the actual alignment A.sub.IST to the setpoint alignment A.sub.SOLL, the alignment module 134 may have an actuator device 16.

[1210] A documentation module 93 may be arranged downstream of the alignment module 134. By means of the documentation module 93, the cable 1a may in particular be marked for a subsequent documentation of the plug connector assembly process. For example, in FIG. 71 an optical marking 21 by means of a laser 20 is indicated.

[1211] The alignment module 134 and the documentation module 93 may form a first module Group M1 of processing modules (shown using dashed lines) and for example be arranged in a common module housing.

[1212] One or more fitting modules, in particular at least one above-described multiple fitting module 50 and/or one above-described single fitting module 59, may be arranged downstream of the documentation module 93 or of the first module group M1 in order to push the later required plug connector components 26, 44, 45, 46, 47 onto the cable 1a in the required sequence. By way of example, only a single fitting module is illustrated in FIG. 71. The fitting modules may together form a second module group M2 (shown using dashed lines) and for example be arranged in a common module housing.

[1213] A stripping module 35 may be arranged downstream of the one or more fitting modules or of the second module group M2 in order to strip a part 5a of the cable sheath 5 of the cable 1a.

[1214] A cable foil processing module 135 may optionally be arranged downstream of stripping module 35 for stripping the cable sheath 5 in order to remove a cable foil 136, which is situated under the cable sheath 5, of the cable 1a.

[1215] The cable foil processing module 135 may have at least one heating wire, at least one blade, at least one molding tool, at least one cold-supplying device, at least one pulling-off aid, at least one suction-extraction device and/or at least one supply device for chemical substances in order to treat at least an outer layer, which faces away from the cable central axis M, of the previously at least partially exposed cable foil 136 in order to remove the cable foil 136 or in order to at least to reduce its mechanical strength for the purposes of assisting the removal of the cable foil 136. The cable foil processing module 135 may also have means for twisting and/or bending the cable section that has the cable foil 136. Before the cable foil 136 is finally removed (for example is pulled off the cable end 3, 4 together with the part 5a of the cable sheath 5), the cable foil 136 may optionally be compressed in the axial direction along the central cable axis M.

[1216] An assembly module 137 for assembling the support sleeve 15 may be arranged downstream of the cable foil processing module 135. The assembly module 137 or a further processing module arranged downstream may furthermore be designed to process the cable shielding braid 6 of the cable 1a, in particular to cut it to a defined length and/or to brush it straight and/or to turn it back over the support sleeve 15.

[1217] A cleaning module 117 may be arranged downstream of the assembly module 137 for assembling the support sleeve 15, in order to remove particles 118 from the cable end 3, 4 that have formed as a result of the previous mechanical processing operations.

[1218] A fabric tape assembly module 138 may be arranged downstream of the cleaning module 117 in order to adhesively apply the fabric tape 9 in order to safeguard the cable la against protruding individual strands of the cable shielding braid 6.

[1219] Further stripping modules 35, in particular a stripping module 35 for removing the filler layer 7 and a stripping module 35 for the purposes of removing a part 2.2a of the insulation 2.2 of the inner conductor 2, may be arranged downstream of the fabric tape assembly module 138.

[1220] The processing modules, starting from the stripping module 35 for stripping the cable sheath 5 up to the stripping module 35 for stripping the insulation 2.2 of the inner conductor 2, may form a third module group M3 (shown using dashed lines) and for example be arranged in a common module housing.

[1221] An assembly module 139 for assembling inner conductor contact elements 8 on the inner conductors 2 of the cable 1a may be arranged downstream of the stripping module 35 for removing the part 2.2a of the insulation 2.2 of the inner conductor 2 or of the third module group M3. In particular, provision may be made for the inner conductor contact elements 8 to be crimped to the inner conductors 2. The assembly module 139 for assembling the inner conductor contact elements 8 may be part of a fourth module group M4.

[1222] Once again, a cleaning module 117 may be arranged downstream of the assembly module 139 for assembling the inner conductor contact elements 8 or of the fourth module group M4, followed by a quality monitoring module 109 for checking (and optionally also for documenting) the quality of the preceding processing steps. The cleaning module 117 and the quality monitoring module 109 may form a fifth module group M5 (shown using dashed lines) and for example be arranged in a common module housing.

[1223] An assembly module 29 for assembling the contact part carrier 13 may be provided downstream of the cleaning module 117 and of the quality monitoring module 109 or of the fifth module group M5. In order to check for correct assembly of the contact part carrier 13, a sensor module 103 may be provided as part of the assembly module 29 or may be arranged downstream of the assembly module 29. Furthermore, an assembly module 140 for compressing or for assembling the shielding sleeve 26 on the contact part carrier 13 may be arranged downstream of the assembly module 29 and the sensor module 103. Finally, a final assembly module 141 may be provided. The processing modules mentioned in this paragraph preferably form a common fourth module group M4 (shown using dashed lines) and may for example be arranged in a common module housing.

[1224] The workpiece carrier system 94 of the transport device 72 preferably transports the cable 1a in each case at least between the processing modules of a common module group M1, M2, M3, M4. Between the module groups M1, M2, M3, M4, the gripper device 132 or a production technician may preferably take over the onward transport of the cable 1a with the assistance of the roller conveyor 133. However, this is not absolutely necessary. In principle, the cable 1a may be transported by the transport device 72 in any desired manner.

[1225] An advantageous variant of the apparatus 131 for assembling a single-core electrical plug connector 12, which by way of example has two single-core cables 1b, is shown in FIGS. 74 to 76, wherein, for the sake of a clearer illustration, the apparatus 131 once again is illustrated in a manner distributed across multiple figures (along the transport direction T).

[1226] With regard to the assembly of a single-core plug connector 12, an arrangement of processing modules in accordance with the following sequence has proven to be particularly suitable. The processing modules mentioned below may in particular have features of the processing modules described above.

[1227] An alignment module 134 for aligning the electrical cable 1b may for example be provided as first processing module within the apparatus 131. The alignment module 134 may be configured to, for the processing of the single-core cable 1b, initially determine an actual alignment and a setpoint alignment A.sub.SOLL of a plug connector component 26, 44, 45, 46, 47, which has been assembled on the second cable end 4, of a second plug connector 12 (as long as the second cable end 4 already has a plug connector component 26, 44, 45, 46, 47 or a second plug connector 12), in order to then adapt the actual alignment A.sub.IST to the setpoint alignment A.sub.SOLL, the alignment module 134 may have an actuator device 16.

[1228] A documentation module 93 may be arranged downstream of the alignment module 134. By means of the documentation module 93, the cable 1b may in particular be marked for a subsequent documentation of the plug connector assembly process. For example, in FIG. 74 an optical marking 21 by means of a laser 20 is indicated.

[1229] The alignment module 134 and the documentation module 93 may form a first module group M1 of processing modules (shown using dashed lines) and for example be arranged in a common module housing.

[1230] One or multiple fitting modules, in particular at least one above-described multiple fitting module 50 and/or one above-described single fitting module 59, may be arranged downstream of the documentation module 93 or of the first module group M1 in order to push the later required plug connector components 26, 44, 45, 46, 47 onto the cable 1b in the required sequence. By way of example, only a single fitting module is illustrated in FIG. 74. The fitting modules may together form a second module group M2 (shown using dashed lines) and for example be arranged in a common module housing.

[1231] A stripping module 35 may be arranged downstream of the one or more fitting modules or of the second module group M2 in order to strip a part 5a of the cable sheath 5 of the cable 1b.

[1232] A cable foil processing module 135 may optionally be arranged downstream of the stripping module 35 for stripping the cable sheath 5 in order to remove a cable foil 136, which is situated under the cable sheath 5, of the cable 1b. The cable foil processing module 135 may have the features which have already been mentioned above.

[1233] An assembly module 137 for assembling the support sleeve 15 may be arranged downstream of the cable foil processing module 135. The assembly module 137 or a further processing module arranged downstream may furthermore be designed to process the cable shielding braid 6 of the cable 1b, in particular to cut it to a defined length and/or to brush it straight and/or to turn it back over the support sleeve 15.

[1234] A cleaning module 117 may be arranged downstream of the assembly module 137 for assembling the support sleeve 15, in order to remove particles 118 from the cable end 3, 4 that have formed as a result of the previous mechanical processing operations.

[1235] An assembly module 142 for compressing the crimp sleeve 71 on the support sleeve 15 may be arranged downstream of the cleaning module 117. Here, the cable shielding braid 6 may advantageously be pressed in between the support sleeve 15 and the crimp sleeve 71.

[1236] A further stripping module 35 may be arranged downstream of the assembly module 142 for compressing the crimp sleeve 71 in order to strip a part 2.2a of the insulation 2.2 of the inner conductor 2.

[1237] The processing modules, starting from the stripping module 35 for stripping the cable sheath 5 up to the stripping module 35 for stripping the insulation 2.2 of the inner conductor 2, may form a third module group M3 (shown using dashed lines) and for example be arranged in a common module housing.

[1238] Once again, a cleaning module 117 may be arranged downstream of the stripping module 35 for removing the part 2.2a of the insulation 2.2 of the inner conductor 2 or of the third module group M3, followed by a quality monitoring module 109 for checking (and optionally also for documenting) the quality of the preceding processing steps. The cleaning module 117 and the quality monitoring module 109 may form a fifth module group M5 (shown using dashed lines) and for example be arranged in a common module housing.

[1239] An assembly module 139 for assembling the inner conductor contact element 8 may be arranged downstream of the cleaning module 117 and of the quality monitoring module 109 or of the fifth module group M5. The inner conductor contact element 8 may preferably be welded, for example ultrasound-welded, to the inner conductor 2 of the cable 1b. The assembly module 139 for assembling the inner conductor contact element 8 may be part of a fourth module group M4.

[1240] A further cleaning module 117 may be arranged downstream of the assembly module 139 for assembling the inner conductor contact element 8 or of the fourth module group M4, for example as part of a fifth module group M5.

[1241] An assembly module 143 for assembling the insulating housing 70, in particular for assembling the insulating housing 70 on the inner conductor contact element 8, may be arranged downstream of the cleaning module 117. The insulating housing 70 may preferably receive the inner conductor contact element 8 within it. The insulating housing 70 may preferably be of multi-part, in particular two-part form and, after the inner conductor contact element 8 has been inserted into one of the shell halves, may be joined together with the other shell half and fixed. A press-in module 69 may be arranged downstream of the assembly module 143 for assembling the insulating housing 70 in order to press the cable end 3, 4 fitted with the insulating housing 70 and with the inner conductor contact element 8 into a plug connector housing 44. Finally, a final assembly module 141 may be provided. The processing modules mentioned in this paragraph preferably form a common fourth module group M4 (shown using dashed lines) and may for example be arranged in a common module housing.

[1242] After a first plug connector 12 has been assembled on one of the cable ends 3, 4 of the cable 1a, 1b, provision may be made for the cable 1a, 1b to be fed back to the apparatus 131 for the assembly of a second plug connector 12 on the opposite cable end 3, 4. For this purpose, the cable 1a, 1b or the work-piece carrier 11 may be correspondingly turned round or over, wherein the orientation of the first plug connector 12 is preferably detected for the assembly of the second plug connector 12, or it is ensured that the orientation of the first plug connector 12 is known during the assembly of the second plug connector 12.

[1243] It may be provided that, within the apparatus 131, processing modules 18, 19, 29, 35, 50, 59, 69, 93, 103, 109, 117, 134, 135, 137, 138, 139, 140, 141, 142, 143 are intentionally skipped or omitted during the plug connector assembly process. For example, it may be provided that multiple examples of some or all of the processing modules 18, 19, 29, 35, 50, 59, 69, 93, 103, 109, 117, 134, 135, 137, 138, 139, 140, 141, 142, 143 for different cable types (for example cable diameters) and/or plug connector types to be assembled are arranged in the production line along the transport direction T. The processing modules 18, 19, 29, 35, 50, 59, 69, 93, 103, 109, 117, 134, 135, 137, 138, 139, 140, 141, 142, 143 may therefore process or not process the cable 1a, 1b as required. The identifier or the marking 21, 23 of the cable 1a, 1b, of the workpiece carrier 11 or of the sheath clamp 48a, 48b, 48c, 48d may be used for the decision as to whether the cable 1a, 1b is to be processed in a respective processing module 18, 19, 29, 35, 50, 59, 69, 93, 103, 109, 117, 134, 135, 137, 138, 139, 140, 141, 142, 143. In this way, the apparatus 131 can be used in a very particularly modular and efficient manner for the plug connector assembly process.

[1244] For example, it is possible in particular for different fitting modules to be provided for fitting the plug connector components 26, 44, 45, 46, 47, 56 for different cable diameters of the cable 1a, 1b. Furthermore, it is for example also possible for different assembly modules 140 to be provided for assembling the support sleeve 15 for different cable diameters. For example, it is also possible for different assembly modules 139 to be provided for assembling the inner conductor contact elements 3 for different cable diameters.

[1245] In order to yet further increase the throughput of the cables 1a, 1b or in order to reduce the process time, provision may optionally be made for several examples of module groups M1, M2, M3, M4, M5 and/or individual processing modules 18, 19, 29, 35, 50, 59, 69, 93, 103, 109, 117, 134, 135, 137, 133, 139, 140, 141, 142, 143, in particular processing modules that require a longer processing time than other processing modules, to be provided in the apparatus 131.

[1246] For example, multiple (for example two, three, four or five) examples of the assembly module 139 for assembling the inner conductor contact elements 8 of the single-core cable 1b, in which the conductor 2.1 of the cable 1b is preferably ultrasound-welded to the inner conductor contact element 8, may be provided, because the welding process generally takes a relatively long time.

[1247] By means of the apparatus 131 according to the invention, an electrical cable 1a, 1b can be fully fabricated starting from an endless cable, following which the cable 1a, 1b can then be fitted with one or two plug connectors 12 and removed from the apparatus 131 in a defined fabrication length L. All processing steps may be recorded in documentation 96 and assigned to the cable 1a, 1b or to its plug connectors) 12.