Connectorized Mass Interconnect Guide for Error-Free COTS Cable Alignment

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Solution Overview

Problem

Mass interconnects face issues with complex wire bundles, incorrect connections, and pin damage due to custom wiring, leading to signal integrity degradation and increased troubleshooting time.

Innovation Solution

A connectorized mass interconnect guide with a body and partitions that divides connector pins into sets, providing apertures for orderly connection of COTS cables without the need for PCBs, soldering, or adaptors, ensuring correct alignment and reducing the risk of pin damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If custom wiring or intermediate circuit boards are used to connect test instruments to mass interconnects, then connection flexibility is improved, but device complexity and troubleshooting difficulty increase

Engineering Contradiction:

Improveconnection flexibilityVSAvoidtotal number of connections

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The mass interconnect frame is segmented into multiple pin sets, with each pin set independently accessible through a removable connector. This segmentation allows test instruments to connect to specific pin sets without requiring complex custom wiring or intermediate circuit boards, thereby reducing overall device complexity while maintaining connection flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A removable connector acts as an intermediary between test instruments and the mass interconnect pin sets. This mediator provides a standardized interface that simplifies connections, eliminating the need for custom wiring while maintaining adaptability. The connector can be easily attached and detached, providing flexibility without increasing permanent device complexity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If custom wiring is used to connect mass interconnects, then connection adaptability is improved, but signal integrity deteriorates due to additional connections

Engineering Contradiction:

Improveconnection adaptabilityVSAvoidsignal integrity

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The intermediate circuit boards and custom wiring are extracted from the connection path. Instead, test instruments connect directly to the mass interconnect pin sets through removable connectors. This elimination of intermediate components maintains signal integrity by reducing the number of connection points where signal degradation could occur, while still providing connection adaptability through the removable connector interface.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If mass interconnects use large wire bundles or direct custom wiring, then connection versatility is improved, but troubleshooting difficulty increases

Engineering Contradiction:

Improveconnection versatilityVSAvoidtroubleshooting difficulty

Core Design Contradiction:

Adaptability or versatilityVSDifficulty of detecting and measuring

Solution Approach 1:

The mass interconnect is segmented into multiple discrete pin sets, each accessible through removable connectors. This segmentation allows troubleshooters to isolate and test individual pin sets independently, dramatically reducing troubleshooting difficulty compared to large wire bundles where problems are difficult to locate. Connection versatility is maintained through the ability to connect to different pin sets as needed.

Inventive Principle:

Principle #1Segmentation

4Adaptability or versatility

If connector pins are exposed for custom wiring, then connection flexibility is improved, but pin damage risk increases

Engineering Contradiction:

Improveconnection flexibilityVSAvoidpin damage risk

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

A removable connector serves as an intermediary that protects the mass interconnect pins during connection operations. The connector provides a robust interface for attaching test instruments, eliminating the need to directly handle and manipulate exposed pins. This reduces pin damage risk while maintaining connection flexibility through the removable connector interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The connector is designed to be attached to the mass interconnect before wiring operations begin. This preliminary action establishes a protected interface that guides and protects pins during subsequent connection operations, reducing the risk of damage while maintaining the flexibility needed for various wiring configurations.

Inventive Principle:

Principle #10Preliminary action

Data Source

PatentUS20240347987A1Connectorized mass interconnect

Publication Date: 2024.10.17 HONEYWELL FEDERAL MANUFACTURING & TECHNOLOGIES LLC

AI summary

A connectorized mass interconnect guide for interfacing a mass interconnect having a plurality of connector pins with a plurality of commercial off-the-shelf (COTS) cables. The connectorized mass interconnect guide broadly comprises a body and a number of partitions forming a number of apertures. The partitions divide connector pins into a number of connector pin sets when the body abuts the mass interconnect. The apertures expose the connector pin sets for receiving the COTS cables being connected to the connector pin sets.