Back Pad D-Ring Orientation and Load Indicator Design
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Solution Overview
Problem
Conventional safety harnesses face difficulties in attaching a lanyard or snap hook to a D-ring after donning, and existing impact indicators increase manufacturing costs and can fail due to complex assemblies.
Innovation Solution
A back pad system with spaced back straps and a connector attachment that captures the D-ring in an upright position using detents, and a load indicator with areas of reduced strength to visibly distort or break under significant force, eliminating the need for costly biasing mechanisms and reducing assembly complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional D-ring attachments are used in safety harnesses, then the structure is simple, but the attachment of lanyards becomes difficult after donning due to the D-ring hanging downward
Solution Approach 1:
The D-ring is pre-positioned in an upright orientation within the back pad assembly before use, preventing it from hanging downward. This preliminary positioning action eliminates the need for users to manually reposition the D-ring during attachment, making lanyard connection straightforward while maintaining structural simplicity through the use of gravity-responsive positioning features
2Ease of operation
If biasing mechanisms are added to maintain D-ring upright position, then ease of operation improves, but device complexity and manufacturing cost increase
Solution Approach 1:
The back pad assembly uses gravity-responsive positioning features that automatically maintain the D-ring in an upright position without requiring external biasing mechanisms. The structure self-regulates through gravitational force, eliminating springs, motors, or other active components while ensuring the connector remains readily accessible for attachment
Solution Approach 2:
The invention replaces expensive, complex biasing mechanisms with simple, passive gravitational positioning features. These lightweight, passive structures achieve the same functional outcome at minimal cost, using basic geometric design rather than engineered active systems
3Measurement precision
If complex impact indicators are used, then measurement precision improves, but reliability decreases due to assembly failures
Solution Approach 1:
The impact indicator is extracted as a separate, independently attachable component rather than being integrated into the main harness structure. This separation allows the indicator to be easily removed, replaced, or inspected without affecting the harness assembly, improving reliability while maintaining precise impact detection through dedicated sensor placement
4Measurement precision
If multiple components are assembled for impact indicators, then measurement capability improves, but manufacturing time and assembly failures increase
Solution Approach 1:
The impact indicator is designed as a modular segment that can be independently manufactured and then attached to the harness. This segmentation allows parallel manufacturing of components, reducing overall production time while maintaining accurate impact detection capabilities through the dedicated indicator design
Solution Approach 2:
The impact indicator is pre-assembled and tested as a complete functional unit before attachment to the harness. This preliminary assembly and testing action ensures the indicator works correctly while simplifying the main harness manufacturing process, reducing both production time and assembly failures
Data Source
AI summary
A back pad system for use in connection with a safety harness which includes at least two spaced back straps and a connector adapted to be connected to a line or lanyard. In one form, the system includes a back pad having passages through which the two back straps can be passed to be crossed over the connector, an attachment to which the connector can be moveably attached, and at least one member that captures the connector in an upright position upon application of force such as manual force (either directly or indirectly) to the connector to move the connector to the upright position.