Optical Connector Assembly Tool With Ratcheted Lever Insertion
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Solution Overview
Problem
The manufacturing of optical connectors is inefficient due to the difficulty in properly pushing the spring push into the housing, especially when the biasing force of the ferrule is high, leading to the need for rework and reduced efficiency.
Innovation Solution
A manufacturing tool with a concave part, handle, and ratchet mechanism that allows for the spring push to be easily locked into the housing using a leveraged operation, ensuring proper positioning and preventing back movement during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual pushing method is used to insert spring push into housing, then operation simplicity is maintained, but pushing reliability deteriorates when biasing force is large
Solution Approach 1:
A dedicated tool body with concave part is introduced as an intermediary device between the operator and the spring push-housing assembly. The tool body provides a structured interface with contact parts that properly engage with the spring push, mediating the force transmission and ensuring reliable insertion even against large biasing forces from the ferrule spring.
Solution Approach 2:
The manual direct pushing method is replaced with a mechanical tool system that incorporates leverage principles. The connecting shaft and handle mechanism transform the operator's input force into amplified pushing force on the spring push, substituting the inadequate manual pushing with a mechanical force multiplication system.
2Force
If leverage principle is used to amplify operation force, then pushing force is improved, but device complexity increases
Solution Approach 1:
The tool is segmented into distinct functional modules: a tool body with concave part for holding the assembly, a connecting shaft for force transmission, and a handle for operator input. This segmentation allows each component to perform its specific function efficiently while keeping the overall structure manageable and not overly complex.
Solution Approach 2:
The connecting shaft enables rotational movement in a different dimension rather than direct linear pushing. By converting the operator's linear handle movement into rotational motion of the connecting shaft, which then translates to linear pushing force, the tool achieves leverage without requiring a complex multi-component mechanical advantage system.
3Ease of operation
If handle movement direction is aligned with contact part movement direction, then operation intuitiveness is improved, but tool compactness deteriorates
Solution Approach 1:
The handle is configured to move in a direction perpendicular to the movement direction of the contact part. The connecting shaft acts as a pivot, converting the handle's lateral movement into axial pushing motion of the contact part. This dimensional transformation achieves compact tool design while maintaining operational intuitiveness through the pivot mechanism.
4Loss of time
If spring push is not properly pushed into housing, then manufacturing time is reduced initially, but manufacturing efficiency deteriorates due to rework
Solution Approach 1:
The tool body with its concave part and contact parts provides inherent feedback through proper mechanical engagement. When the contact part successfully pushes the spring push into the housing, the mechanical geometry of the tool ensures the correct insertion depth and positioning. This built-in feedback mechanism prevents improper assembly without requiring additional inspection steps or causing rework.
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
The tool enhances manufacturing efficiency by facilitating easy and secure locking of the spring push into the housing, improving assembly precision and reducing the need for rework.
Implementation Method 1
a ratchet biasing member that biases the second engaging part
Implementation Method 2
a handle biasing member that biases the handle toward the stand-by position
Implementation Method 3
when the handle moves between the stand-by position and the push-into position, a direction in which the operating part moves and a direction in which the contact part moves are different with each other
Data Source
AI summary
A manufacturing tool for an optical connector includes: a tool body that includes a concave part; a handle that includes an operating part and a contact part; and a connecting shaft that rotatably connects the handle to the tool body. The handle is rotatable between: a stand-by position, and a push-into position in which a larger portion of the contact part is disposed inside the concave part than in the stand-by position. A direction in which the operating part moves is different from a direction in which the contact part moves.