Bayonet Cable Strain Relief for Electrical Devices
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Solution Overview
Problem
Existing strain relief methods for electrical devices are inefficient and labor-intensive, particularly when fastening multiple rigid cables with large cross-sections, as they require crimping and screw connections, making them unsuitable for mass-produced devices.
Innovation Solution
An electrical device design featuring a housing with cable ports, a retaining cap, and a sleeve with a radially extending annular face, where the retaining cap engages over the sleeve's fixing section to securely fasten the cable, utilizing a bayonet connection for quick assembly and enhanced strain relief.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional strain relief methods (crimping and screw connections) are used to fasten rigid cables with large cross-sections, then reliable cable fixation is achieved, but assembly effort and time expenditure increase significantly
Solution Approach 1:
The cable fastening system is divided into separate functional components: a cable port for structural support, a retaining cap for strain relief, and a sleeve for positioning. This segmentation allows each component to be optimized independently and assembled quickly without complex operations like crimping or screwing.
Solution Approach 2:
The retaining cap integrates multiple functions: it provides strain relief by clamping the cable, positions the sleeve via the passage opening, and connects to the cable port. This merging of functions into a single component reduces assembly steps and eliminates the need for separate fastening operations.
2Reliability
If multiple cables are fastened to the housing using traditional methods, then each cable is securely fixed, but the assembly process becomes increasingly time-consuming and labor-intensive
Solution Approach 1:
The cable port is pre-formed with an integrated retaining cap during housing manufacturing. This preliminary action eliminates the need for separate fastening operations when multiple cables need to be installed, as each cable port is already prepared with strain relief functionality.
Solution Approach 2:
The retaining cap design is universal and can be applied to multiple cable ports simultaneously. Each cable port with its integrated retaining cap functions independently but follows the same design principle, allowing standardized quick assembly for devices with multiple cables without increasing complexity.
3Strength
If rigid connecting cables with large cross-sections are fastened using housing part joining, then strain relief is provided, but the method is not suitable for mass production due to high assembly effort
Solution Approach 1:
The retaining cap is designed to automatically clamp and secure the rigid cable when the sleeve is inserted and the retaining cap is attached to the cable port. This self-service mechanism eliminates the need for manual crimping or screw tightening operations, making the process suitable for automated mass production while maintaining strong strain relief capability.
Data Source
AI summary
An electrical device includes a housing, a retaining cap, and a sleeve. The housing has a cable port through which a cable is led into the housing. The retaining cap has a passage opening through which the cable is led through the retaining cap. The sleeve has a fixing section resting against a sheath of the cable and an annular face extending radially with respect to the cable. In an assembled state of the electrical device, the retaining cap is joined to the sleeve and fixes the sleeve to the cable port with the passage opening of the retaining cap engaging over the fixing section of the sleeve and an edge surface of the passage opening pressing the fixing section against the sheath of the cable. Further in the assembled state, the retaining cap and the cable port may be connected to one another by a bayonet connector.