Captive Connector Saver for Serviceable Space Interfaces
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Solution Overview
Problem
Existing connector savers are not well adapted for use in harsh environments like outer space, where connectors in space robotics and tooling interfaces experience degradation due to environmental exposure and are often non-serviceable, requiring complex and impractical maintenance procedures.
Innovation Solution
A connector saver device with a body featuring first and second apertures, jacking fasteners with retaining elements, and alignment ports, designed to securely attach to and easily remove from a target connector, reducing the number of connection cycles and facilitating replacement, while being suitable for space applications with features like captive fasteners and a tethering point.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors are integrally secured to harness cables in space applications, then the connectors are protected from environmental degradation, but the connectors become inaccessible and non-serviceable requiring complex maintenance procedures
Solution Approach 1:
The invention divides the connector system into separable components: a serviceable connector portion that can be accessed and replaced, and a harness cable portion that remains fixed. This segmentation allows maintenance personnel to access and replace connectors without complex disassembly while maintaining protection during operation.
Solution Approach 2:
The invention introduces an intermediary retention mechanism (such as a bayonet-style connector or quick-disconnect interface) between the connector and harness cable. This intermediary allows for rapid connection and disconnection, enabling serviceability while maintaining secure attachment during operation.
2Productivity
If connectors are subjected to multiple connection cycles, then the connectors can be reused, but mechanical or electrical degradation arises reducing performance
Solution Approach 1:
The invention treats connectors as disposable or limited-life components that can be quickly replaced rather than maintained indefinitely. By designing connectors for easy replacement, the system accepts that connectors will degrade after a certain number of cycles but ensures continuous operation through rapid substitution of degraded units.
Solution Approach 2:
The invention implements a process where degraded connectors are discarded (removed from service) and replaced with new or refurbished units. The removed connectors can be recovered, refurbished, and returned to service, creating a lifecycle management system that maintains reliability while allowing extensive reuse through controlled replacement cycles.
3Ease of operation
If connector savers are designed for easy removal, then maintenance is simplified, but the connector savers may not be securely attached during operation
Solution Approach 1:
The invention employs a dynamic retention mechanism that adapts its holding strength based on operational state. During operation, the mechanism provides strong secure attachment (high strength). During maintenance, the same mechanism allows easy release (easy removal) through a simple action such as rotating a release lever or pressing a button that disengages the retention feature.
Solution Approach 2:
The invention uses asymmetric retention features where the engagement direction requires significant force (for secure attachment) while the disengagement direction requires minimal force (for easy removal). For example, a bayonet connector may require quarter-turn engagement with firm resistance but simple reverse rotation for release, creating asymmetric strength characteristics that satisfy both requirements.
Data Source
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AI summary
Connector savers and associated methods are provided. A connector saver includes a body comprising first and second apertures, a first connector disposed on a surface of the body and for transmitting electrical current, and first and second jacking fasteners for securing the connector saver and removing the connector saver. The first jacking fastener is for disposing in the first aperture and the second jacking fastener is for disposing in the second aperture. Each of the first and second jacking fasteners include a retaining element coupled to a shaft of the respective jacking fastener that is configured such that the respective jacking fastener is not separable from the body.