U-Shaped Cradle Tool for Electrical Connector Assembly

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Solution Overview

Problem

Operators face challenges in connecting large electrical connectors due to the high forces required, which can lead to muscle fatigue and increased risk of Musculoskeletal Disorders (MSDs), and may be difficult for those with lower strength or using only one hand, affecting productivity and compliance with accessibility standards.

Innovation Solution

An electrical connector tool featuring U-shaped cradles mounted on a bar clamp, which reduces the force needed to connect large electrical connectors by squeezing them together, allowing for reduced muscle fatigue and enabling operators with lower strength or one-handed use.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If operators manually connect large electrical connectors, then the task can be completed, but high forces are required causing muscle fatigue and MSDs

Engineering Contradiction:

Improveease of connector connectionVSAvoidforce required to connect connectors

Core Design Contradiction:

Ease of operationVSForce

Solution Approach 1:

A bar clamp tool is introduced as an intermediary device between the operator and the electrical connectors. The tool includes two cradles that hold the connectors and a bar clamp mechanism that applies controlled force to push the connectors together, eliminating the need for operators to directly exert high forces

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The manual mechanical action of pushing connectors together is replaced by a bar clamp mechanical system. The bar clamp uses a screw mechanism or ratcheting system to convert rotational or intermittent hand movements into continuous linear force, providing mechanical advantage to reduce operator effort

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If operators use high forces to connect connectors, then connections are achieved, but risk of Musculoskeletal Disorders increases

Engineering Contradiction:

Improveconnection reliabilityVSAvoidrisk of MSDs

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The bar clamp tool serves as a mediator that ensures reliable connector connections through controlled, progressive force application while protecting operators from harmful high forces. The tool distributes and manages the force required for connection, preventing direct transmission of harmful loads to the operator's musculoskeletal system

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If high strength is required for connector connection, then connections are achieved, but operators with lower strength cannot perform the task

Engineering Contradiction:

Improveoperator strength requirementVSAvoidaccessibility to operators with disabilities

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The mechanical system replaces the need for high operator strength by using a bar clamp mechanism with mechanical advantage. The tool can be operated by individuals with varying strength levels, including those with disabilities, as it converts small hand movements into large connection forces through its mechanical design

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The bar clamp tool provides universal accessibility for connector connection tasks. It can be used by operators regardless of their strength capabilities, making the task accessible to individuals with disabilities and complying with ADA requirements while maintaining connection reliability

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS11038315B2Electrical connector tool

Publication Date: 2021.06.15 THE BOEING CO

AI summary

An apparatus configured to assist an operator in connecting electrical connectors. The apparatus includes a first U-shaped cradle and a second U-shaped cradle. Each of the cradles has a contact surface on a front side that is configured to contact a flange on an electrical connector. Each of the cradles also includes a jaw mount configured to mount on a jaw member of a bar clamp.