Aircraft Wire Clamp Assembly Tool-Free Installation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current clamp assemblies for securing wire bundles to aircraft structures are time-consuming, costly, and ergonomically challenging, often requiring extended installer presence in confined spaces, and can cause damage to wires due to over-pressure engagement, leading to noncompliance with wiring standards.
Innovation Solution
A clamp assembly with a body having a curvilinear second portion, a hinge pin or flange, and a latch member, along with a strap member that can be rotatably coupled to the body, allowing for tool-free installation and maintaining the centerline position of the wire carrying opening, reducing the risk of wire damage and ensuring compliance with wiring regulations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single piece clamp with opposing apertures is used, then the wire bundle can be securely confined, but the installation becomes time-consuming and ergonomically challenging
Solution Approach 1:
The clamp assembly is divided into two separate components: a clamp body and a clamp strap. The clamp body can be independently secured to the structure, while the clamp strap is flexible and can be positioned around the wire bundle. This segmentation allows the installer to complete the clamp body attachment first, then add the wire bundle and secure the strap, eliminating the need to hold the entire assembly together during installation.
Solution Approach 2:
A latch mechanism serves as an intermediary component that connects the clamp strap to the clamp body. The latch provides a simple engagement interface where the strap can be quickly secured to the body without requiring complex alignment or multiple fasteners, significantly reducing the time and effort needed for installation.
2Reliability
If the installer manually positions and aligns the clamp components, then proper securement is achieved, but ergonomic challenges arise in confined spaces
Solution Approach 1:
The clamp body is pre-positioned and secured to the structure before the wire bundle is installed. This preliminary action establishes the mounting location and orientation in advance, so the installer does not need to manually align and hold multiple components simultaneously in difficult-to-reach areas. The wire bundle is then simply placed into the already-positioned clamp body and secured with the strap.
3Ease of operation
If a zip-tie configuration is used to close the clamp, then tool-free installation is possible, but over-pressure can damage the wires
Solution Approach 1:
The latch mechanism is designed with a controlled engagement parameter that limits the closing force applied to the wire bundle. Instead of allowing unlimited tension like a zip-tie, the latch engages at a predetermined force level that is sufficient to secure the clamp strap but controlled to prevent excessive pressure that could damage the wires. This parameter change transforms the force application from uncontrolled to controlled.
4Adaptability or versatility
If the clamp assembly is designed with multiple components, then installation flexibility improves, but device complexity increases
Solution Approach 1:
The clamp body is designed as a universal mounting component that can be secured to various aircraft structures using standard fastening methods. The latch mechanism serves multiple functions: it connects the strap to the body, controls the closing force, and provides a simple release mechanism. This multi-functionality reduces the need for additional specialized components, keeping the overall complexity manageable while maintaining installation flexibility.
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 clamp assembly enables quick, easy, and reliable installation of wire bundles without tools, reducing labor costs and maintaining the centerline position to meet wiring standards, thereby minimizing rework and wire damage.
Implementation Method 1
one of a hinge pin or hinge flange associated with the first end of the second portion and a latch member connected to the body. The latch member extends in a direction away from the second end of the second portion
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Clamp assembly for securing wire bundles to a structure includes a body having a first portion having a first side and a second portion having a second side which extends in a curvilinear direction between a first end and a second end. The assembly further includes one of a hinge pin or hinge flange is associated with the first end of the second portion and a latch member connected to the body. The latch member extends in a direction away from the second end of the second portion with a termination edge positioned spaced apart from the second end of the second portion and the termination edge extends in a direction in angular relationship to the curvilinear direction of the second side. A strap member is included having the other of the one of the hinge pin or the hinge flange and an end portion which engages the latch member.