Self-Aligning Connector Assembly for Tool-Free Replacement
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Solution Overview
Problem
Existing connector devices for exercise equipment and similar apparatuses often require tools for assembly and alignment, are not easily replaceable, and can be costly to maintain due to the need for replacing entire structural components when threaded connections fail.
Innovation Solution
A connector assembly comprising a base part with a through-hole and an aperture, along with a device that has a bolt-hole and angled outer surfaces, allowing for self-fixturing and self-aligning connections via a bolt, eliminating the need for tools and enabling modular, replaceable attachments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional connector devices are used for exercise equipment, then structural components can be connected, but tools are required for assembly and alignment, and replacement is difficult
Solution Approach 1:
The connector device features self-aligning and self-fixturing capabilities through its geometric design. The angled outer surfaces automatically orient the device correctly when inserted into the aperture, and the bolt-hole alignment features ensure proper positioning without requiring external tools or complex alignment procedures. This self-service mechanism eliminates the need for tools during assembly and simplifies the overall process.
Solution Approach 2:
The connector device is designed as a modular component that can be easily replaced independently of other structural components. The device separates the connection function from the structural elements, allowing individual replacement of the connector device when threaded connections fail, rather than requiring replacement of entire structural components. This segmentation improves maintainability and reduces replacement complexity.
2Ease of repair
If traditional connector devices are used, then connections can be made, but entire structural components must be replaced when threaded connections fail, increasing maintenance costs
Solution Approach 1:
The connector device is designed as a replaceable module that separates the connection function from the structural components. When threaded connections fail, only the connector device itself needs to be replaced, not the entire structural component. This segmentation enables targeted replacement of the faulty element, reducing material waste and maintenance costs.
Solution Approach 2:
The design allows for easy discarding of the failed connector device and recovery/reuse of the structural components. The modular nature of the connector device enables it to be removed and replaced without damaging or compromising the structural elements, allowing those components to be recovered and reused in future installations.
3Ease of manufacture
If traditional connector devices are used, then components can be connected, but tools and complex alignment procedures are required, increasing manufacturing and assembly costs
Solution Approach 1:
The connector device incorporates self-aligning features through its geometric design. The angled outer surfaces and bolt-hole positioning automatically guide the device into correct orientation when inserted into the aperture, eliminating the need for complex alignment procedures or specialized tools during assembly. This reduces manufacturing complexity and associated costs.
Solution Approach 2:
The connector device uses asymmetric geometric features, including angled outer surfaces and specifically positioned bolt-holes, to ensure automatic alignment during assembly. This asymmetric design provides built-in alignment guidance that simplifies the assembly process and reduces the need for complex alignment procedures, thereby lowering manufacturing and assembly costs.
Data Source
AI summary
A connector assembly comprises a base part that defines a through-hole for receiving a bolt and also defines an aperture for receiving a device having a first end that fits through the aperture in the base part and a second end that does not fit through the aperture in the base part. The first end of the device defines a bolt-hole for engaging with a bolt extending though the through-hole in the base part. The second end of the device comprises opposing outer surfaces that engage the base part and thereby prevent the device from passing completely through the aperture, and also align the bolt-hole in the device with the through-hole in the base part when the first end of the device is inserted into the aperture.