Connector Housing Contact Installation Apparatus

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Solution Overview

Problem

Installing electrical contacts into connector housings is time-consuming, difficult, and requires precise alignment and force control to avoid under- or over-insertion, which is challenging with conventional tools and methods.

Innovation Solution

An apparatus and method featuring a base with an alignment guide and a carrier that is translatably and pivotally coupled, along with a tool holder providing controlled movement and force application to ensure precise alignment and insertion of electrical contacts into connector housings, preventing binding or misalignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional electrical contact insertion tools and methods are used, then the installation process can be completed, but the process is time-consuming, difficult to perform properly, and tiring for the operator

Engineering Contradiction:

Improveinstallation speedVSAvoidoperator effort

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The apparatus divides the insertion process into distinct functional components: a base for positioning the connector housing, an alignment guide for maintaining coaxial alignment, a carrier for holding and moving the insertion tool, and a tool holder with controlled degrees of freedom. This segmentation allows each component to perform its specific function efficiently, reducing overall installation time and operator fatigue.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The alignment guide acts as an intermediary element between the base and the insertion tool, ensuring proper alignment without requiring the operator to manually adjust positioning. The carrier serves as an intermediary mechanism that translates and pivots to position the tool holder, automating the alignment process and reducing operator effort.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If precise alignment and force control are required to avoid under- or over-insertion, then installation accuracy is improved, but the process becomes more difficult and time-consuming

Engineering Contradiction:

Improvealignment accuracyVSAvoidprocess complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The tool holder is designed with dynamic degrees of freedom: one degree of freedom relative to the carrier and three degrees of freedom relative to the base. This dynamic design allows the tool holder to automatically adapt to positioning requirements while maintaining precise alignment, achieving accurate insertion without requiring overly complex control mechanisms.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The alignment guide and tool holder design enable self-alignment through their geometric constraints and degrees of freedom. The system automatically positions the insertion tool coaxially with the socket through the inherent mechanical design, eliminating the need for complex manual alignment procedures or additional alignment devices.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If the operator must not under-advance or over-advance the insertion tool, then insertion precision is improved, but the difficulty of performing the task increases

Engineering Contradiction:

Improveinsertion depth controlVSAvoidtask difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of operation

Solution Approach 1:

The apparatus incorporates preliminary positioning features in the alignment guide and carrier design that pre-establish the correct insertion depth before the actual insertion force is applied. The tool holder's constrained degrees of freedom ensure the tool advances to the precise required position automatically, preventing both under- and over-advancement without requiring the operator to judge the correct depth.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The design replaces manual depth judgment and control with a mechanical system of constrained degrees of freedom and geometric alignment. The tool holder's movement is mechanically limited to three degrees of freedom relative to the base, which inherently controls the insertion depth and prevents operator error in depth judgment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11329442B2Methods for installing electrical contacts into a connector housing

Publication Date: 2022.05.10 THE BOEING CO

AI summary

An apparatus (100) for installing at least one electrical contact (152) into a connector housing (150) comprises a base (110) configured to fixedly support the connector housing (150), an alignment guide (122), extending from the base (110) and having a central axis (164), and a carrier (124), translatably and pivotally coupled with the alignment guide (122). With the connector housing (150) fixedly supported by the base (110), the alignment guide (122) is configured to be parallel to an insertion axis (160) of a socket (154) of the connector housing (150), and the carrier (124) is movable parallel to the insertion axis (160). The apparatus (100) additionally comprises a tool holder (132), coupled to the carrier (124). The tool holder (132) has a working axis (162), only one degree of freedom relative to the carrier (124), and only three degrees of freedom relative to the base (110).