Insulating Pin Sleeves for Connector Testing Protection
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Solution Overview
Problem
In electrical connectors used in commercial airplanes, it is challenging to accurately identify and protect pins from incorrect potential application during pin injection testing, which can lead to damage and human error due to the large number of pins and the need for manual counting.
Innovation Solution
Fitting electrical insulating sleeves around pins that should not have potential applied during testing, using materials like heat shrink tubing that can be easily secured and removed without leaving residue, to differentiate them from pins that are to be tested.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plate is installed over the electrical connector to cover all pins, then protection from incorrect potential application is improved, but accessibility of pins for testing deteriorates
Solution Approach 1:
The single plate covering all pins is segmented into individual pin covers or selectively removable sections. This allows specific pins to be exposed for testing while other pins remain covered for protection, resolving the contradiction between comprehensive protection and selective accessibility.
Solution Approach 2:
The plate is designed with pre-defined openings or removable sections corresponding to test pins, allowing testing to be performed without removing the entire plate. This preliminary configuration maintains protection for non-test pins while providing immediate access to test pins.
2Device complexity
If manual counting is used to identify pins for testing, then simplicity of the system is improved, but accuracy of pin identification deteriorates
Solution Approach 1:
Different colors or visual markers are applied to pins that require testing versus pins that should be protected. This visual differentiation eliminates the need for manual counting and reduces human error, while adding minimal complexity through simple color-coding or labeling.
Solution Approach 2:
Visual markers or color-coded indicators serve as an intermediary between the pin identification system and the operator. This intermediary provides immediate visual guidance for pin selection, replacing error-prone manual counting with intuitive visual recognition.
3Ease of operation
If the plate is removed to access a specific pin, then accessibility of the specific pin is improved, but protection of other pins deteriorates
Solution Approach 1:
The plate is divided into individually removable sections or pin-specific covers. This allows removal of only the specific section needed for testing while leaving other sections in place to protect their respective pins, eliminating the need to remove the entire plate for single-pin access.
Solution Approach 2:
The plate transitions from a static, all-or-nothing coverage structure to a dynamic system where specific sections can be selectively removed or opened. This dynamic configuration allows flexible access to individual pins while maintaining protection for the remainder of the connector.
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
Prevents accidental application of potential to incorrect pins, reducing the risk of damage and human error by clearly distinguishing testable pins from non-testable pins, ensuring safe and effective pin injection testing.
Implementation Method 1
The sleeve may be made of heat shrink material that is shrunk onto the pin
Data Source
AI summary
One embodiment includes a method for protecting from the accidental application of an electrical potential to an incorrect pin of a multipin electrical connector during testing. A sleeve is fitted around a pin that is not to have potential applied to it such that the pin is protected from accidental application of potential during testing.