Elbow Connector Obstruction Mechanism for Blind-Mate Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing elbow connectors for cable assemblies suffer from installation issues due to blind mating, leading to incomplete connections where the fastener is not fully inserted into the lug aperture, resulting in unreliable electrical connections.
Innovation Solution
The implementation of a fastener assembly with a connecting rod and bumper mechanism that transitions between blocking and non-blocking positions, ensuring proper alignment and complete insertion of the fastener into the lug aperture, facilitated by a bumper that moves in response to alignment, allowing for reliable electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If blind mating is used for fastener insertion, then device complexity is reduced, but reliability of connection deteriorates due to incomplete insertion
Solution Approach 1:
The bumper provides tactile feedback to the installer when the lug reaches its fully inserted position. This feedback mechanism allows the installer to know when proper alignment and insertion have been achieved without requiring complex visual alignment tools or multiple installation steps, thus maintaining simplicity while improving reliability
Solution Approach 2:
The bumper acts as an intermediary element between the lug and the installer. It mediates the insertion process by providing a physical stop that indicates when the lug is properly positioned, eliminating the need for complex alignment mechanisms while ensuring reliable connection
2Reliability
If visual alignment is required for fastener insertion, then connection reliability is improved, but ease of operation deteriorates due to difficult alignment
Solution Approach 1:
The bumper provides immediate tactile feedback when the lug reaches full insertion, eliminating the need for visual alignment checks. The installer can rely on the tactile signal from the bumper to confirm proper positioning, making the operation easier while maintaining reliability
Solution Approach 2:
The bumper system is self-service in that it automatically provides alignment confirmation during the insertion process. The tactile feedback from the bumper self-corrects any misalignment issues without requiring the installer to perform additional alignment operations or visual inspections
3Ease of operation
If tactile feedback is provided during insertion, then ease of operation is improved, but device complexity increases due to additional components
Solution Approach 1:
The bumper serves as a simple intermediary component that provides tactile feedback without adding significant complexity. It is a straightforward mechanical element that interfaces between the lug and the housing, providing installation guidance through its physical stop function
Solution Approach 2:
The bumper concept can be copied from simpler mechanical systems where tactile feedback is already used. The design leverages the proven effectiveness of simple mechanical feedback elements rather than introducing complex new mechanisms
Data Source
AI summary
An elbow connector receives a cable assembly having a lug with a lug aperture. The elbow connector comprises a receiving cavity for the lug of the cable assembly and a fastener assembly. The fastener assembly has a connecting rod, a fastener tube, and a fastener. The fastener is configured for movement within the fastener tube. The connecting rod has a bumper for engaging the lug and an obstruction element for engaging the fastener. The connecting rod is moveable between (i) a blocking position in which the obstruction element indicates the fastener is unaligned with the lug aperture, and (ii) a non-blocking position in which the fastener is free of the obstruction element and aligned with the lug aperture. The connecting rod transitions to the non-blocking position in response to the lug moving the bumper to a point where the fastener and the lug aperture are aligned.