Connector Saver with Captive Jacking Fasteners for Cycle Wear
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Solution Overview
Problem
Electrical connectors in space applications face degradation due to harsh environments and are often non-serviceable, making replacement difficult and impractical, especially when integrated into complex or expensive equipment.
Innovation Solution
A connector saver device with jacking fasteners and retaining elements that secure and remove the saver from a target connector, allowing for easy replacement and extension of the connector's life cycle, featuring captive fasteners, redundant connectors, and alignment ports for secure mating and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connectors are integrally secured to harness cable in space applications, then connector reliability is improved, but connector serviceability deteriorates making replacement difficult and impractical
Solution Approach 1:
The invention divides the connector system into two separable parts: a permanent connector that remains integrated with the harness cable, and a replaceable connector saver that interfaces with the permanent connector. This segmentation allows the permanent connector to maintain its reliable integral connection while the connector saver can be independently replaced when degraded, thus resolving the contradiction between reliability and serviceability.
Solution Approach 2:
The connector saver acts as an intermediary component between the external electrical interface and the permanent connector. It absorbs the wear and degradation from connection cycles, environmental exposure, and incidental damage, protecting the permanent connector while allowing easy replacement of the saver itself when needed.
2Reliability
If connectors are subjected to harsh environments including abrasive dusts and extreme temperatures, then connector durability is tested, but connector connection cycle life deteriorates
Solution Approach 1:
The connector saver is designed as a replaceable component that absorbs the harsh environmental conditions and connection cycle wear. When the saver degrades after a certain number of cycles in harsh environments, it can be replaced without replacing the entire permanent connector assembly, effectively extending the operational life of the system while the saver performs its sacrificial protective function.
3Ease of operation
If array of fasteners and retention features are removed to access deteriorated connector, then connector accessibility is improved, but procedure complexity increases making it unfeasible or impractical
Solution Approach 1:
The invention extracts the accessibility problem from the permanent connector by making the connector saver a separately replaceable component. The connector saver can be accessed and replaced without removing the array of fasteners and retention features that secure the permanent connector to the harness cable. This extraction allows routine maintenance to be performed easily while the permanent connector remains securely installed.
Data Source
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.