Bundle cable connector assembly, components, tooling and manufacturing method

A method for assembling a bundle cable connector assembly, said method comprising:

• providing a least one electrical wire including an inner conductor and an outer dielectric shield;
• stripping the dielectric shield from the at least one electrical wire to form an exposed tip portion;
• positioning the end of the wire including the tip portion within an internal bore of a connector pin;
• crimping the connector pin so as to electrically connect the inner conductor to the pin;
• mounting the pin to a connector body;
• and
• mounting a wire-locking device to the wire and the connector body where the wire-locking device holds the wire within the connector body.

A method for assembling a bundle cable connector assembly, said method comprising:

• providing a least one electrical wire including an inner conductor and an outer dielectric shield;
• stripping the dielectric shield from the at least one electrical wire to form an exposed tip portion, an exposed bird cage preventative zone and a crimping zone therebetween that includes the dielectric shield;
• tinning the electrical wire by depositing a solder coating on the inner conductor at the bird cage preventative zone and the tip portion;
• removing the dielectric shield around the crimping zone;
• positioning the end of the wire including the tip portion, the crimping zone and the bird cage preventative zone within an internal bore of a connector pin;
• crimping the connector pin proximate to the bird cage preventative zone and the crimping zone so as to electrically connect the inner conductor to the pin, wherein crimping the connector pin proximate to the bird cage preventative zone and the crimping zone includes using a crimping tool having a plurality of probes where the probes receive an electrical current to heat the solder at the birdcage preventative zone;
• mounting the pin to a connector body;
• and
• mounting a wire-locking device to the wire and the connector body where the wire-locking device holds the wire within the connector body and where mounting a wire-locking device to the wire and the connector body includes securing a holding ferrule to the wire and positioning a locking ring around the holding ferrule and between annular rims on the connector body.