Modular Electrical Connection Forming Tool with Actuator
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Solution Overview
Problem
Current circuit wiring products lack safety features and require tedious manual assembly, leading to time-consuming construction operations and difficulties in using hand-made electrical connections for plug and play wiring systems.
Innovation Solution
An electrical connection forming tool with a wire forming die module, including a module housing, coil sliding body feature, die, locking feature, and actuator, which aligns with an electrical plug, imprints a wire onto the plug, and facilitates easy assembly and disassembly through a pumping mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual assembly is used for electrical connections, then ease of operation is maintained, but productivity is reduced and assembly time increases
Solution Approach 1:
The tool is divided into modular components including a wire forming die module, actuator housing, and actuator mechanism. This segmentation allows the complex assembly process to be broken down into manageable parts that can be operated sequentially, maintaining ease of operation while improving overall productivity through systematic organization of the assembly steps.
Solution Approach 2:
The actuator mechanism provides dynamic motion to automatically position and secure the electrical plug to the junction box. This dynamic element replaces static manual fastening operations, enabling faster assembly while maintaining operational simplicity through automated movement sequences.
2Device complexity
If hand-made electrical connections are used, then device complexity is reduced, but reliability is compromised due to lack of safety features
Solution Approach 1:
The wire forming die module pre-forms and positions wires before final assembly, ensuring proper alignment and secure attachment. This preliminary action embeds safety features into the assembly process itself, maintaining reliability while avoiding excessive complexity by integrating safety functions into existing assembly steps.
Solution Approach 2:
The locking mechanism automatically engages and secures the electrical plug to the junction box without requiring additional manual intervention. This self-service feature ensures consistent safety standards are met while keeping the device structure simple and easy to operate.
3Productivity
If automated actuator mechanism is added, then productivity is improved, but device complexity increases
Solution Approach 1:
The actuator mechanism serves multiple functions: it positions the electrical plug, activates the locking mechanism, and ensures proper wire alignment. This multi-functionality improves productivity by consolidating multiple operations into a single mechanism, while avoiding increased complexity through functional integration rather than adding separate components.
Solution Approach 2:
The actuator housing integrates the actuator mechanism with the wire forming die module and locking feature into a unified assembly. This merging approach improves productivity by creating a coordinated system, while managing complexity through integrated design that eliminates the need for separate housing and mounting structures.
Data Source
AI summary
A method of manufacturing an electrical connection forming tool, the method including selecting, a wire forming die module, the wire forming die module including a module housing, wherein the module housing includes a front side, the front side including a chamber configured to align with an electrical plug; a back side; and an inner compartment, the inner compartment including a coil sliding body feature, the coil sliding body feature configured to interface with the electrical plug; a die, and the die is configured to accept a wire and imprint the wire on the electrical plug; a locking feature; and a cover for the locking feature; and connecting an actuator and an actuator housing to the selected wire forming die module.