Lanyard Assembly Visual Wire Insertion Verification
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Solution Overview
Problem
Conventional lanyard assemblies face challenges in determining if a wire end is fully accepted by the connector body before crimping, which can reduce wire-pulling capacity, and they lack features to enhance anchoring and detachment of wires from cores during winding and unwinding processes.
Innovation Solution
A lanyard assembly with a connector body that includes a window for visual confirmation of wire insertion and projection-defining means to maximize surface area contact, allowing for improved wire-pulling capacity and efficient anchoring and detachment of wires from cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the inserted wire end is fully accepted by the connector body when crimped, then the wire-pulling capacity is maximized, but it is difficult to determine whether the wire end is fully accepted before crimping
Solution Approach 1:
The patent employs color-coded depth indicators on the connector body that change or become visible at specific wire insertion depths. These visual indicators (different colors or color patterns) allow users to immediately recognize when the wire has been inserted to the correct depth, ensuring maximum wire-pulling capacity without requiring complex measurement tools or procedures.
Solution Approach 2:
The patent adds a visual dimension to the wire insertion verification process by incorporating depth indicators that provide information in a different dimension (visual feedback) rather than requiring physical measurement. This allows users to determine wire insertion depth through visual inspection of color-coded markers or windows on the connector body, transforming a difficult measurement task into an easy visual confirmation.
2Strength
If conventional connector bodies are used without additional features, then the structure remains simple, but the wire-pulling capacity is reduced due to insufficient wire acceptance
Solution Approach 1:
The patent divides the connector body into functional segments: a crimping portion for securing the wire, a body portion with depth indicators for verification, and an opening for wire insertion. This segmentation allows each portion to be optimized for its specific function while maintaining overall structural simplicity. The depth indicators are integrated as distinct visual elements within the body portion rather than requiring separate complex mechanisms.
Solution Approach 2:
The patent incorporates depth indicators and visual verification features into the connector body design before the crimping operation occurs. This preliminary visual guidance ensures that the wire is correctly positioned and fully accepted by the connector body prior to crimping, maximizing wire-pulling capacity from the outset without requiring additional steps or complex adjustment mechanisms during the crimping process.
Data Source
AI summary
A wire-anchoring system for use with a core about which a wire is desired to be wound utilizes a lanyard assembly which includes a cord portion and a connector body connected to the cord portion. The elongated connector body has two opposite ends and a hollow interior including an opening which opens out of the body at one end thereof and into which the terminal end of the wire can be inserted for purposes of anchoring the wire to the connector body. In addition, the cord portion of the wire has a free end which is securable to the outer surface of the core adjacent the securement location thereon so that by securing the free end of the cord portion to the outer surface of the core and anchoring the terminal end of the wire to the connector body, the wire is anchored to the core for an operation involving the winding of the wire about the core.