Motorcycle Starter Contact Alignment Tool Design
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Solution Overview
Problem
The installation of motorcycle starter contacts often results in premature failure due to improper alignment, as users struggle to balance and tighten them using their thumbs, leading to discomfort and inefficient installation processes.
Innovation Solution
A starter contact alignment tool system comprising a tool plate attachable to the motorcycle starter solenoid, a threaded rod with a cylindrical handle, and a contact jig that aligns internal electrical contacts by inserting through the tool plate aperture, ensuring correct positioning and secure tightening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If users balance contacts with their thumb and tighten them manually, then they can install the contacts, but the contacts are installed at an angle resulting in premature failure
Solution Approach 1:
The patent introduces an alignment tool as an intermediary device between the user's hand and the electrical contacts. The tool includes a guide body that fits into the solenoid housing and a contact alignment feature that physically guides the contacts into proper alignment, eliminating the need for manual balancing with the thumb while ensuring correct installation angle.
Solution Approach 2:
The patent replaces the manual mechanical balancing action (using the thumb to balance contacts) with a mechanical guidance system. The alignment tool uses a guide body and contact alignment feature that mechanically enforce proper contact positioning, substituting the imprecise manual balancing action with a structured mechanical guidance mechanism.
2Productivity
If users manually balance and tighten starter contacts, then they can complete the installation, but the process causes pain and discomfort
Solution Approach 1:
The alignment tool serves as an intermediary that mediates between the installation process and the user's hand. By providing a guided insertion path and proper positioning through the guide body and contact alignment feature, the tool eliminates the need for uncomfortable manual balancing actions while maintaining installation efficiency.
3Manufacturing precision
If no alignment tool is used, then the installation process is simple, but the contacts are not properly aligned
Solution Approach 1:
The alignment tool is segmented into distinct functional components: a guide body that fits into the solenoid housing, a contact alignment feature that positions the contacts, and a handle for operation. This segmentation allows each component to perform its specific function while keeping the overall design relatively simple and easy to manufacture.
Solution Approach 2:
The alignment tool performs preliminary alignment action before the final tightening of the contacts. By pre-positioning the contacts correctly using the guide body and contact alignment feature, the tool ensures proper alignment is established before the final installation step, improving precision without requiring complex multi-step procedures.
Data Source
AI summary
A motorcycle starter contact alignment tool is configured to be an adaptation of a solenoid tool plate incorporating a threaded aperture to adjustably control the advancement of a threaded rod and a contact jig. The threaded rod is intended to depress the contact jig, having an alignment face which coincidentally contacts a pair of electrical contacts within the solenoid housing, so as to properly align those contacts prior to being tightened in position. The threaded rod is provided with a handle to facilitate the turning thereof.