Connector Contact Insertion and Retention Testing With Force Feedback
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Solution Overview
Problem
Existing methods for inserting and testing the retention of electrically conductive contacts in electrical connectors are inconsistent and prone to improper seating, leading to potential disconnection under vibration or excessive force, with manual testing methods lacking precision and consistency.
Innovation Solution
An apparatus and method involving an insertion tip and a test probe that automatically insert and test the retention of contacts within electrical connectors, using controlled forces and position sensors to ensure proper seating and retention, with automated feedback for error detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual insertion and testing methods are used, then operational flexibility is maintained, but insertion consistency and retention reliability deteriorate due to inconsistent operator force application
Solution Approach 1:
The system performs self-testing by automatically applying force through the test probe to verify contact retention after insertion, eliminating the need for separate manual retention testing operations while ensuring consistent force application
Solution Approach 2:
The patent replaces manual mechanical insertion and testing with an automated mechanical system that applies controlled forces through the insertion tip and test probe, substituting human operator actions with a automated mechanical process that ensures consistent force application
2Productivity
If excessive force is applied during manual insertion, then contact insertion speed increases, but contact damage and connector damage occur
Solution Approach 1:
The system changes the force parameter from uncontrolled manual application to controlled automated application, maintaining insertion speed while preventing excessive force through regulated mechanical actuation of the insertion tip
Solution Approach 2:
The system uses feedback from position sensors and force monitoring to adjust insertion parameters in real-time, ensuring that sufficient force is applied for proper insertion while preventing excessive force that would cause damage to contacts or connectors
3Object-affected harmful factors
If insufficient force is applied during manual insertion, then contact damage is avoided, but improper seating occurs leading to tenuous connections
Solution Approach 1:
The system optimizes the force parameter through controlled mechanical actuation, ensuring that sufficient force is applied to achieve proper contact seating and reliable retention while avoiding the extremes of both excessive and insufficient force application
4Ease of operation
If manual retention testing is performed, then operational simplicity is maintained, but measurement precision and test consistency deteriorate due to inability to gauge pulling or pushing force
Solution Approach 1:
The patent replaces manual retention testing with an automated mechanical testing system that applies controlled forces through the test probe and measures retention force with precision, substituting imprecise human judgment with accurate mechanical measurement
5Reliability
If automated insertion and testing systems are implemented, then insertion consistency and retention reliability improve, but device complexity increases
Solution Approach 1:
The system merges the insertion and retention testing functions into a single integrated automated process, where the insertion tip performs insertion and the test probe performs retention testing, reducing overall system complexity through functional integration
Solution Approach 2:
The automated system performs multiple functions including controlled insertion, retention testing, and error detection through a single integrated apparatus, providing multi-functionality that justifies the increased device complexity through enhanced capability
Data Source
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AI summary
Apparatus and methods for inserting and retention testing an electrically conductive contact (4a, 4b) in an electrical connector (2). The method includes the following steps: manually partially inserting the contact into a hole (1) formed inside the electrical connector; inserting the contact further into the hole by pushing the contact along an axis using an insertion tip (41) that is aligned with the axis and that displaces in a first direction along the axis during inserting; and after inserting the contact further into the hole, testing retention of the contact inside the electrical connector by pushing the contact along the axis using a test probe (46) that is aligned with the axis and that displaces in a second direction opposite to the first direction during retention testing. The force exerted by the test probe on the contact is less than a specified contact retention force. The method further includes generating an alert signal if the test probe displaces along the axis in the second direction by more than a specified distance during retention testing.