Control Cable Adapter Assembly for Secure Tool-Free Replacement
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Solution Overview
Problem
Control cables used to transfer mechanical energy for mechanical functions require precise and secure attachment while being easy to install and replace, posing challenges due to high demands on user-friendliness and integration with digital systems in compact spaces.
Innovation Solution
A control system with a lever, housing, and adapter elements that allow for easy assembly and disassembly of control cables without bending or complex handling, using form-fitted coupling mechanisms and perpendicular assembly directions to secure the cables in place, reducing the need for intrusive system modifications during installation or replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If control cables are securely fixed in their intended positions using traditional methods, then reliability of mechanical function is improved, but ease of installation and replacement deteriorates
Solution Approach 1:
The control cable assembly is segmented into modular components: a control cable, an adapter element, and a housing with recesses. The adapter element acts as an intermediate segment that couples the cable to the housing through form-fitted connections, allowing the cable to be securely fixed while enabling easy replacement by simply detaching the modular adapter-cable assembly from the housing recess.
2Manufacturing precision
If control cables require precise positioning and secure attachment, then manufacturing precision is improved, but device complexity worsens
Solution Approach 1:
The adapter element serves as an intermediary component that simplifies the coupling mechanism. It features a first recess that form-fits onto a protrusion in the housing, and a second recess that form-fits onto the control cable. This intermediate adapter element achieves precise positioning through the form-fitted geometry while reducing overall device complexity by providing a standardized, reusable coupling interface between the housing and cable.
3Ease of operation
If control cables are made easy to install and replace, then ease of operation is improved, but reliability of secure attachment deteriorates
Solution Approach 1:
The form-fitted coupling mechanism utilizes parameter changes in the geometric dimensions of the adapter element and housing recess. The protrusion and recess are designed with specific dimensional parameters that create an interference fit, generating frictional forces and normal forces that securely attach the cable while still allowing for tool-free installation and replacement. The secure attachment is achieved through optimized dimensional parameters rather than complex fastening mechanisms.
4Ease of manufacture
If traditional control cable installation methods are used, then ease of manufacture is maintained, but loss of time during installation and maintenance increases
Solution Approach 1:
The adapter element is pre-assembled with the control cable in a preliminary action, creating a ready-to-install assembly. The adapter's first recess is pre-configured to form-fit onto the housing protrusion, and the second recess is pre-configured to form-fit onto the cable. This preliminary preparation allows the entire cable assembly to be quickly installed by simply inserting the pre-assembled adapter-cable unit into the housing recess, significantly reducing installation and maintenance time while maintaining ease of manufacture through standardized components.
Data Source
AI summary
A control system (1) for operating a mechanical function is disclosed. The system (1) includes a lever (11), a housing (13) and at least one control cable (3). The lever (11) is pivotable and includes at least one seat (9) for receiving a first coupling element (17) of the at least one control cable (3). The control system (1) further includes at least one adapter element (23), and the housing (13) further includes at least one first recess (25). The at least one seat (9) of the lever and the at least one first recess (25) of the housing (13) include first and second open spaces (33, 35) that are aligned with each other in an assembly direction (37). This allows for a simultaneous coupling of the first coupling element (17) to the at least one seat (9) and the adapter element (23) to the at least one first recess (25) of the housing (13), along said assembly direction (37).