Hinged Strain Relief Backshell for Connector Maintenance
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Solution Overview
Problem
Traditional strain relief backshells require the entire connector to be removed for replacement, leading to increased maintenance burdens and risks of additional damage during installation and removal, especially in aircraft applications where two-piece assemblies can be difficult to align and secure properly.
Innovation Solution
A hinged connector strain relief backshell design featuring two semi-cylindrical halves with complementary half-threads, wrench flats, and a hinge pin mechanism allows for easy assembly and replacement without removing the entire connector, providing strain relief and reducing Foreign Object Debris risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a traditional solid backshell is used, then the connector is securely protected, but the entire connector must be removed for backshell replacement, increasing maintenance burden and risk of damage
Solution Approach 1:
The backshell is divided into two separate semi-cylindrical halves that can be assembled around the connector independently. This segmentation allows each half to be installed separately and then joined together, enabling backshell replacement without removing the entire connector assembly.
Solution Approach 2:
The two semi-cylindrical halves are joined together using fasteners that secure them to each other and to the connector, merging them into a unified protective structure that functions as a complete backshell while maintaining the advantage of separable installation.
2Ease of operation
If a two-piece backshell assembly is used, then backshell replacement is easier, but it is difficult to retain the two pieces in proper position or alignment during installation
Solution Approach 1:
The fasteners are positioned asymmetrically on the two semi-cylindrical halves, with specific locations designed to guide proper alignment during assembly. This asymmetric positioning ensures that the halves can only be correctly oriented one way, facilitating proper alignment without requiring complex alignment procedures.
Solution Approach 2:
The fasteners serve as intermediary elements that not only secure the two halves together but also guide their alignment during installation. The fastener holes are positioned and sized to accommodate alignment tolerances while ensuring proper final positioning.
3Reliability
If the backshell is securely fastened to the connector, then strain relief is effective, but replacement requires complete connector removal
Solution Approach 1:
The backshell is segmented into two halves that are each independently fastened to the connector. This segmentation allows the backshell to maintain secure attachment for strain relief while enabling replacement by removing and reassembling the two halves separately rather than removing the entire connector.
Solution Approach 2:
The backshell design transitions from a static, permanently attached structure to a dynamic, replaceable structure. The two semi-cylindrical halves can be separated, removed, and reinstalled, providing the flexibility needed for maintenance while maintaining secure attachment during operation.
Data Source
AI summary
A hinged strain relief backshell, selectively disposed about a cable, adjacent to a cable connector for selective assembly with the connector, includes a first integral semi-cylindrical backshell half and a second integral semi-cylindrical backshell half second hinged to the first integral backshell half. The integral semi-cylindrical backshell halves configured to be to be selectively disposed about the cable with one another. Each integral semi-cylindrical backshell half defining complementary half-threads defined by the respective backshell half and corresponding wrench flats defined in an outside surface portion of each backshell half. At least one of the integral semi-cylindrical backshell halves defining at least one strain clamp ear portion extending from a connector distal portion of the backshell half for retraining the cable at least in a direction parallel to the cable.