Hand-operated Tool with Visual Feedback for Ground Stud Mounting
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Solution Overview
Problem
The challenge in the car industry is to reliably mount electrical terminals onto stud contacts attached to car bodies made from lightweight materials, which can become loose during installation and are often difficult to access and control, especially with modern cars having limited installation spaces.
Innovation Solution
A hand-operated tool with a hollow receptacle and a stud detector arrangement that provides visual feedback through an indicator element, such as a light-emitting LED, to confirm correct installation of the terminal onto the stud contact, along with a latching assembly for secure attachment and automatic disengagement, and a terminal extractor section for easy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection of stud contact installation is attempted in cramped spaces, then installation verification is possible, but accessibility and visual control become difficult
Solution Approach 1:
The patent implements a feedback mechanism through an indicator element that provides visual confirmation of correct stud contact installation. The indicator element changes appearance (e.g., color change from red to green, or illumination) when the stud detector arrangement confirms proper installation, allowing operators to verify installation quality without direct visual inspection of the hard-to-reach stud contact.
Solution Approach 2:
The patent introduces an intermediary indicator element that mediates between the stud contact installation state and the operator's visual perception. Instead of requiring direct observation of the stud contact in cramped spaces, the indicator element serves as an intermediary that conveys installation status to the operator from an accessible location.
2Reliability
If excessive force is applied during terminal mounting to ensure secure connection, then connection reliability improves, but the ground stud may come loose from lightweight car body materials
Solution Approach 1:
The stud detector arrangement provides real-time feedback during the mounting process, allowing the operator to apply force progressively and stop when the correct installation state is achieved, as indicated by the indicator element. This prevents application of excessive force that could damage the ground stud attachment to lightweight car body materials.
Solution Approach 2:
The indicator element provides advance indication of the correct installation state, allowing the operator to know when to stop applying force. This preliminary visual feedback prevents the need to apply excessive force as a precaution, thereby protecting the ground stud attachment integrity.
3Device complexity
If traditional mounting tools are used without installation confirmation, then mounting process is simple, but installation correctness cannot be verified
Solution Approach 1:
The patent incorporates a feedback mechanism through the indicator element that automatically indicates when the stud contact is correctly installed. This maintains relative simplicity of the mounting tool while adding verification capability - the indicator element provides automatic confirmation without requiring complex measurement or inspection procedures.
Solution Approach 2:
The mounting tool performs self-verification through the stud detector arrangement and indicator element, which automatically detect and indicate correct installation status. This eliminates the need for separate verification steps or complex inspection procedures, maintaining operational simplicity while ensuring installation correctness.
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
Ensures reliable and secure mounting of terminals onto stud contacts, preventing unnecessary force application and ensuring correct installation even in cramped conditions, while allowing for easy extraction of the terminal after successful installation.
Implementation Method 1
such as a light-emitting LED
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a hand-operated tool (22) for mounting a sleeve-like terminal (12) onto a stud contact (4), in particular a ground stud contact attached to a car body (2) and to a ground contact mounting set (112) comprising such a hand-operated tool (22) and the stud contact (4). Further, the invention relates to a method for mounting the terminal (12) onto the stud contact (4). In order to avoid excessive mounting forces while the mounting terminal (12) onto the stud contact (4) and also to ensure that the terminal (12) is correctly installed onto the stud contact (4) even in situations where the stud contact (4) is not clearly visible to an operator, the hand-operated tool (22) comprises a hollow receptacle adapted to receive the terminal (12), the receptacle being open in a mounting direction (34). Further, the hand-operated tool (22) comprises a stud detector arrangement (48) adapted to detect at least a final installation position (50) of the stud contact (4) within the receptacle. An indicator element (36) of the hand-operated tool (22) is operatively connected to the stud connector arrangement and arranged visibly from outside the hand-operated tool. The indicator element (36) comprises a first visual appearance (38) and a second visual appearance (40), which are different from each other. The hand-operated tool is adapted to automatically switch from the first to the second appearance depending on the position of the stud contact within the receptacle. Thus, visual feedback is given to the operator when the installment of the terminal (12) is complete.