Avionic Wire Insertion Tool with Force-Limited Locking
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Solution Overview
Problem
Current tools for inserting and verifying the correct connection of avionic wires into connectors are either cumbersome, risk damaging the wires, or require manual verification that can be error-prone, especially in aircraft systems where vibrations may lead to loose connections.
Innovation Solution
A tool with tubular gripping and guide means that automatically secures the wire during insertion and releases it upon reaching a force threshold, ensuring correct insertion and preventing damage by controlling the force exerted on the wire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an operator manually pulls on the wire to verify correct insertion, then the wire connection can be checked, but the wire may be damaged or degraded due to excessive force
Solution Approach 1:
The tool performs self-verification by automatically detecting whether the wire is correctly inserted into the connector cavity through its sensor system, eliminating the need for manual pulling and force application by the operator
Solution Approach 2:
The patent replaces the manual mechanical verification method (operator pulling the wire) with an automated detection system using sensors and electronic signals to verify wire insertion status, thereby eliminating the harmful mechanical stress on the wire
2Reliability
If an operator exerts force on the wire during verification, then insertion can be tested, but the seal may block extraction even with insufficient force
Solution Approach 1:
The tool autonomously determines wire insertion status by detecting the presence or absence of the wire in the cavity through its sensor system, without requiring the operator to apply force or interpret resistance from the seal
Solution Approach 2:
The system provides immediate feedback through visual or electronic indicators to show whether the wire is correctly inserted, eliminating the need for the operator to infer insertion status from the difficulty of wire extraction
3Productivity
If multiple wires are installed in a connector, then complete systems can be built, but operators may forget to verify each wire individually
Solution Approach 1:
The tool automatically verifies each wire insertion as it is performed, providing immediate feedback for each individual wire without requiring the operator to manually check each connection, ensuring no wire is overlooked even in multi-wire connectors
Solution Approach 2:
The verification process is integrated into the insertion process itself, allowing continuous verification of each wire as it is installed, maintaining productivity while ensuring complete verification of all wires in the connector
4Productivity
If approximate wire insertion is allowed, then installation speed increases, but electrical contact may be lost during use due to vibrations
Solution Approach 1:
The tool ensures correct wire insertion and proper engagement with the connector cavity before the operator releases the wire, verifying the connection is secure and will withstand vibrations during use, preventing the need for rework
Solution Approach 2:
The system provides immediate feedback confirming correct insertion, allowing the operator to proceed with confidence that the connection is proper and will maintain electrical contact under vibration conditions
Data Source
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AI summary
The present invention relates to a tool (10) for inserting a wire (1) into a connector (5) comprising a gripping means (20) and a guiding means (40) having a longitudinal groove. The gripping means (20) contains two pads (61) and a movement means (70) bearing against the clamping means (60). The tool includes a locking means (80) that secures the gripping means (20) and the guiding means (40) in translation along a longitudinal axis (100) in an insertion position (POS2) up to a force threshold, said pads (61) clamping a wire in this insertion position (POS2).