Blind-mate PIM Testing Adapter with Radial Adjustment
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Solution Overview
Problem
Conventional PIM test fixtures for coaxial connectors are prone to inconsistent results due to torque variations during mating, are time-consuming, and lack adjustability for misaligned connectors, making them unsuitable for rapid field operations and multi-port installations.
Innovation Solution
A test fixture with an adapter connector and a foundation that includes a biasing member allowing axial and radial adjustment, eliminating the need for torque wrenches and enabling quick push-on/push-off functionality, compatible with thread-coupling interfaces like 7/16 DIN, and suitable for modular and intensive field operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a coupling nut and threaded coupling mechanism is used to secure the connector to the fixture, then reliable electro-mechanical engagement is achieved, but the mating process becomes time-consuming and requires torque wrenches
Solution Approach 1:
The connector is divided into separate functional components: a push-on connector body for rapid attachment and a separate coupling nut mechanism for securing. This segmentation allows the quick-connect function to be independent from the securing function, enabling rapid mating without torque tools while maintaining reliable engagement through the separate coupling mechanism.
Solution Approach 2:
The fixture includes pre-configured reception features such as recesses and alignment guides that prepare the mating interface in advance. The coupling nut is pre-positioned on the fixture, and the inner contact includes pre-formed engagement features, allowing the connector to be quickly secured without requiring complex assembly steps or torque wrenches.
2Manufacturing precision
If a fixed rigid fixture structure is used, then manufacturing precision is maintained, but adjustability for misaligned connectors is lost
Solution Approach 1:
The fixture incorporates dynamic adjustment mechanisms including movable inner contacts with spring fingers that can flex and adapt to misaligned connectors, and adjustable outer body positioning features. These dynamic elements allow the rigid fixture structure to accommodate variations in connector alignment while maintaining precise electrical and mechanical engagement.
Solution Approach 2:
The fixture includes adjustable parameters such as the position of the inner contact relative to the outer body, the tension of spring fingers, and the positioning of the coupling nut. These adjustable parameters enable the fixture to adapt to different connector configurations and misalignments while maintaining manufacturing precision through controlled adjustment ranges.
3Reliability
If a coupling nut requiring threading is used, then secure engagement is achieved, but the operation becomes complex and difficult in close quarters
Solution Approach 1:
The coupling nut is extracted from the main connector body and positioned as a separate, pre-mounted component on the fixture. This allows the user to simply push the connector onto the pre-positioned coupling nut without requiring threading operations in close quarters. The coupling nut's threading function is preserved for secure engagement, but the operational complexity is reduced by eliminating the need to thread it during mating.
4Manufacturing precision
If a conventional test fixture with fixed geometry is used, then manufacturing precision is maintained, but rapid push-on/push-off functionality and adaptability to misaligned connectors are lost
Solution Approach 1:
The fixture incorporates dynamic elements such as spring fingers on the inner contact that can rapidly deflect during push-on/push-off operations, and movable outer body sections that can quickly adjust to misaligned connectors. These dynamic features enable high-speed testing operations while maintaining precise geometric relationships through controlled flexibility rather than rigid fixed geometry.
Solution Approach 2:
The fixture includes pre-configured alignment features, pre-positioned coupling nuts, and pre-formed engagement surfaces that prepare the mating interface in advance. This preliminary configuration allows connectors to be quickly attached and tested without requiring complex alignment procedures, significantly improving testing speed while maintaining manufacturing precision through pre-established geometric relationships.
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 solution provides consistent and rapid PIM testing with reduced setup time, improved reliability, and adaptability for various connector configurations, enhancing testing efficiency and compatibility with modular systems.
Implementation Method 1
a biasing member exerting an axial force on the sleeve and the outer body, the biasing member permitting axial and radial adjustment of the outer body and inner contact relative to the sleeve
Implementation Method 2
The resilient member is positioned to apply radial pressure to the inner ring of the outer body of coaxial connector to be tested
Data Source
AI summary
A fixture for testing coaxial connectors for PIM includes: (a) an adapter connector comprising an inner contact; an outer body that circumferentially surrounds and that is spaced from the inner contact, the outer body including an inner ring and an outer ring with a gap therebetween; and a resilient member in electrical contact with the outer body; and (b) a foundation including a fixed sleeve and a biasing member, the biasing member exerting an axial force on the sleeve and the outer body, the biasing member permitting axial and radial adjustment of the outer body and inner contact relative to the sleeve. The gap between the inner and outer rings of the outer body is configured to receive an outer ring of an outer body of a coaxial connector to be tested. The inner ring of the test fixture is located to be radially outward of an inner ring of the outer body of the coaxial connector to be tested. The resilient member is positioned to apply radial pressure to the inner ring of the outer body of coaxial connector to be tested.