Reverse Clip Cap Terminal Connector Vibration Resistance
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Solution Overview
Problem
Motion-transmitting remote control cable assemblies face issues with dimensional tolerance ranges in mating components, leading to lash and vibration, requiring high installation loads, and posing challenges in proper orientation and assembly.
Innovation Solution
A terminal sub-assembly with a generally annular isolator and reverse clip cap configuration that interlocks with a connector pin, providing a secure and vibration-resistant connection while allowing for proper orientation and reduced installation loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional isolators are used to absorb vibration, then vibration resistance is improved, but wear and breakdown occur at concentrated force areas
Solution Approach 1:
The terminal assembly uses a composite structure combining a hard reverse clip cap (made of wear-resistant material) with a softer isolator. The hard clip cap protects against wear and breakdown at concentrated force areas, while the softer isolator absorbs vibration. This composite approach resolves the contradiction by assigning different material properties to different functional requirements within the same assembly.
2Strength
If high installation loads are applied to achieve high extraction loads, then connection security is improved, but assembly difficulty increases
Solution Approach 1:
The reverse clip cap incorporates a resilient deflectable wall that dynamically responds to installation forces. During assembly, the wall deflects to accommodate the pin insertion with relatively low installation load. Once installed, the resilient wall maintains high extraction load capacity by elastic recovery. This dynamic behavior resolves the contradiction between easy assembly and strong connection.
Solution Approach 2:
The terminal assembly is segmented into distinct functional components: the isolator for vibration absorption, the reverse clip cap for secure retention, and the deflectable wall for controlled engagement. This segmentation allows each component to be optimized for its specific function, enabling high extraction loads through the clip cap structure while maintaining ease of assembly through the isolator's vibration absorption and the controlled deflection mechanism.
3Adaptability or versatility
If multiple interconnecting parts are used in terminal assemblies, then functionality is improved, but assembly orientation complexity increases
Solution Approach 1:
The reverse clip cap and isolator incorporate asymmetric configuration features including non-circular cross-sections and oriented engagement surfaces. These asymmetric features provide self-aligning characteristics that guide proper orientation during assembly, eliminating the need for complex orientation procedures despite having multiple interconnecting parts. The asymmetry resolves the contradiction by making the correct assembly orientation obvious and self-correcting.
4Ease of manufacture
If dimensional tolerance ranges are large in mating components, then manufacturing cost is reduced, but lash and inaccuracy increase
Solution Approach 1:
The resilient deflectable wall changes its physical state from a flexible assembly aid to a rigid retention structure. During assembly, the wall's flexibility accommodates dimensional variations and tolerance stacks in mating components without creating lash. Once the pin is installed, the wall's elastic recovery creates a rigid, precise connection. This parameter change resolves the contradiction by allowing large tolerances during assembly while achieving high precision in the final assembled state.
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 effectively reduces lash and vibration, maintains high extraction loads, and simplifies assembly by ensuring proper orientation, addressing the challenges of dimensional tolerance and wear in motion-transmitting cable assemblies.
Implementation Method 1
The generally annular isolator has a generally central bore defining a connector pin socket, adapted to receive a connector pin
Implementation Method 2
by their very nature they must be made of a softer material that has significant give or resiliency to absorb the vibration
Implementation Method 3
The connector pin end socket has at least one deflectable wall with configurations for securing such connector pin
Implementation Method 4
The reverse clip cap and isolator have corresponding configurations designed to interlock when the fitting is mated with a connector pin
Data Source
AI summary
A fitting for a terminal connection in a core-adjuster assembly has a generally annular isolator with a generally central bore defining a connector pin socket and a reverse clip cap socket, and a reverse clip cap configured to be received substantially concentrically by the reverse clip cap socket of the isolator and defining a connector pin end socket.