In-Situ Abrading Tool for Electrical Connector Pin Contact Refurbishment
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Solution Overview
Problem
The existing technologies fail to efficiently remove worn plating from pin contacts in electrical connectors, leading to premature discarding of connectors and assemblies, as the plating wears out over time and with repeated use, making refurbishment and re-plating difficult due to limited access and the need for replacement.
Innovation Solution
An abrading tool with an elongated body and a bore, featuring a transverse slot for a removable abrading element, allows for in-situ removal of plating from pin contacts by aligning the element with the pin contact and rotating the tool to abrade the plating, enabling efficient refurbishment and re-plating without dismantling the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire connector assembly is discarded and replaced when plating wears out, then reliability is maintained, but loss of substance and loss of time increase due to waste and replacement downtime
Solution Approach 1:
The invention separates the pin contact (which needs refurbishment) from the rest of the connector assembly. By providing a dedicated refurbishment tool that targets only the pin contact, the system enables selective maintenance of the worn component while preserving the functional connector body, thereby reducing waste and replacement needs
Solution Approach 2:
The invention recovers the pin contact by removing worn plating and preparing it for re-plating, rather than discarding the entire connector assembly. This recovery process extends the service life of the connector components and reduces material waste
2Reliability
If the entire connector assembly is discarded and replaced when plating wears out, then reliability is maintained, but productivity decreases due to replacement downtime
Solution Approach 1:
The invention performs preliminary refurbishment of the pin contact by removing worn plating before re-plating. This preliminary preparation work enables the pin contact to be restored to serviceable condition, avoiding the need for complete assembly replacement and reducing downtime
Solution Approach 2:
Instead of discarding and replacing the entire assembly, the invention recovers the pin contact through plating removal and re-plating processes, maintaining connector functionality and reducing replacement downtime
3Ease of manufacture
If traditional plating removal methods are used, then plating can be removed, but ease of operation deteriorates due to limited access and complex procedures
Solution Approach 1:
The refurbishment tool is designed with a nested structure where the abrading element is positioned within a holder that fits into the connector assembly. This nested configuration allows the tool to access the pin contact through limited space while maintaining the necessary abrading functionality
Solution Approach 2:
The invention introduces an intermediary refurbishment tool that facilitates plating removal. The tool includes an abrading element mounted on a holder with specific geometric features that enable access to the pin contact and provide controlled abrasion, making the operation easier and more accessible
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The tool effectively removes worn plating from pin contacts in situ, allowing for cost-effective refurbishment and re-plating, extending the life of electrical connectors and reducing waste by enabling maintenance without replacing the entire assembly.
Implementation Method 1
an abrading tool for removing plating from pin contacts... the abrading element abrades the plating of the pin contact
Data Source
AI summary
An abrading tool for refurbishing pin contacts in situ in an electrical connector is provided. The abrading tool includes a bore defined in a first end for receiving the pin contacts therein and a transverse slot which intersects the bore. A removable abrading element is received within the slot and positioned therein in alignment with the bore.