Endoscope Steering Wire Assembly for Precise Ratchet Tensioning

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Solution Overview

Problem

Existing endoscope manufacturing processes face challenges in achieving precise and consistent tensioning of steering wires, which is complex and costly, especially in single-use endoscopes, due to high friction and the need for manual handling during glue curing.

Innovation Solution

The introduction of a ratchet rack and rack connector system allows for the decoupling of steering wire connection and tensioning, enabling assembly without initial tension, followed by precise tensioning at a later stage, facilitating automation and reducing manufacturing costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the steering wire is tensioned while connected to the steering actuator using traditional methods (gluing under tension), then the steering wire achieves initial tension, but the assembly process becomes complex and manufacturing precision deteriorates due to difficulty in maintaining correct position and tension simultaneously

Engineering Contradiction:

Improvesteering wire tension precisionVSAvoidassembly process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention separates the steering wire connection and tensioning into two independent stages: first connecting the wire to the ratchet rack without tension, then later tensioning via rack connector translation. This segmentation eliminates the complexity of simultaneous position and tension control during assembly.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The steering wire is connected to the ratchet rack in advance without requiring tensioning equipment or complex positioning fixtures. The tensioning action is deferred to a later stage when the wire is already secured, simplifying the initial assembly process.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the steering wire is tensioned through the wire actuator with high friction (wound onto actuator through openings), then the wire achieves grip and connection, but the actual tension becomes unknown and varies due to friction losses

Engineering Contradiction:

Improvesteering wire connection reliabilityVSAvoidsteering wire tension consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The ratchet rack serves as an intermediary between the steering wire and the tensioning mechanism. The wire connects to the rack without friction, and tension is applied directly to the rack connector, eliminating friction-induced tension variability while maintaining secure connection.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If the steering wire must be kept steady during glue curing to maintain correct tension and position, then the connection becomes permanent, but complex machinery is required and assembly time increases

Engineering Contradiction:

Improveassembly simplicityVSAvoidassembly time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The invention extracts the tensioning function from the gluing process entirely. By using a mechanical ratchet rack connector that translates unidirectionally, the system eliminates the need for glue curing and associated complex positioning machinery, reducing both assembly complexity and time.

Inventive Principle:

Principle #2Taking out (Extraction)

4Manufacturing precision

If traditional steering wire tensioning methods are used, then the wire achieves required tension, but the process is costly and not suitable for automation in single-use endoscopes

Engineering Contradiction:

Improvesteering wire tension accuracyVSAvoidassembly automation capability

Core Design Contradiction:

Manufacturing precisionVSExtent of automation

Solution Approach 1:

The ratchet rack connector performs the tensioning function through its own unidirectional translation mechanism without requiring external tensioning equipment or complex automation systems. The system is inherently suitable for automated assembly in single-use endoscope manufacturing.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach simplifies assembly, reduces manufacturing costs, and ensures precise tensioning of steering wires, improving ergonomics and reducing the risk of injury, while being suitable for both single-use and reusable endoscopes.

Implementation Method 1

The rachet rack enables assembly of the endoscope without tensioning the steering wire and tensioning of the steering wire after assembly by translating the rachet rack unidirectionally through the rack connector

Methodology Applied

Scientific EffectRatchet mechanism: Ratchet

Data Source

PatentUS20250241524A1Endoscope with steering wire assembly

Publication Date: 2025.07.31 AMBU AS

AI summary

Endoscope including a handle with a steering actuator, an insertion cord with a bending section, a first steering wire having a distal end connected to the bending section and a proximal end connected to the steering actuator, a second steering wire having a distal end connected to the bending section and a proximal end connected to the steering actuator, a ratchet rack arranged at a proximal end of at least one of the steering wires, and a rack connector arranged at the steering actuator.