Cable Header Floating Inserts Alignment
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Solution Overview
Problem
Cable headers face misalignment issues due to design tolerances in connector and cable terminals, and require specialized tools for cable removal, which complicates the process.
Innovation Solution
A cable header design featuring floating inserts and a sliding cover plate with geometrically varying through-holes that align and secure cable terminals, allowing for easy removal without specialized tools by adjusting the position of the cover plate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional cable headers are used with fixed inserts, then manufacturing precision is improved, but alignment between cable terminals and connector terminals deteriorates due to tolerance stacking
Solution Approach 1:
The insert is designed to float within the aperture rather than being rigidly fixed, allowing it to dynamically adjust its position to compensate for tolerance variations in cable terminals and connector terminals, thereby maintaining reliable alignment despite manufacturing variations
Solution Approach 2:
The insert's positional parameters are made variable within the aperture space, enabling it to shift to optimal alignment positions based on the specific cable terminal being connected, rather than being constrained to a single fixed position
2Reliability
If traditional cable headers with secured inserts are used, then reliability of connection is improved, but ease of operation deteriorates due to requirement of specialized removal tools
Solution Approach 1:
The cover plate serves a dual function: it secures the floating insert during normal operation and simultaneously provides the release mechanism for cable removal, eliminating the need for specialized tools by using a common screwdriver to operate both functions
Solution Approach 2:
The cover plate is designed to perform multiple functions: securing the floating insert, providing a release mechanism for cable removal, and serving as a protective cover, thereby simplifying the overall device and eliminating the need for specialized removal tools
3Adaptability or versatility
If floating inserts with gaps are used, then alignment flexibility is improved, but device complexity increases due to additional cover plate and fastening mechanisms
Solution Approach 1:
The cover plate merges multiple functions into a single component: it secures the floating insert, provides the release mechanism for cable removal, and serves as a protective cover, thereby reducing overall device complexity despite the added functionality
Data Source
AI summary
Disclosed are apparatuses including a cable header block with apertures for floating inserts and a cover plate. The cable header block includes an aperture pattern that matches a pattern of connector terminals. The floating inserts fit in the apertures of the cable header block. The cover plate can also include a through-hole pattern that matches the aperture pattern. Also, each of the through-holes can include a first geometric shape larger than a cross-section of a cable terminal end and a second geometric shape adjacent to the first shape that is smaller than the cross-section of the cable terminal end. The cover plate retains the floating inserts within the apertures. Also, the cover plate aligns the first geometric shape over the floating inserts when the fastener is in a first position and aligns the second geometric shape over the floating inserts when the fastener is in a second position.