Terminal Connector Flexible Arm Reduces Installation Force
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Solution Overview
Problem
Motion-transmitting cable assemblies often experience imperfect connections due to manufacturing tolerances, leading to uneven fits and increased installation and extraction forces, which can result in lash and inaccuracy in transmission systems.
Innovation Solution
The design of terminal connectors with elongate bodies, arms, and projections that include grooves and tab members to facilitate controlled installation and extraction forces, along with an isolator material and swivel tube to reduce lash and accommodate manufacturing tolerances, allowing for adjustable connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If terminal connectors are designed with fixed rigid structures to ensure precise fit, then manufacturing precision is improved, but installation and extraction forces become excessively large
Solution Approach 1:
The terminal connector incorporates a flexible arm that can bend at a defined location, transforming the rigid structure into a dynamic one. This flexibility allows the arm to deform during installation and extraction, significantly reducing the forces required while maintaining precise fit when engaged. The flexible arm bends to accommodate alignment variations and then locks into position, providing both ease of installation and secure connection.
Solution Approach 2:
The patent changes the physical state of the arm from rigid to flexible by introducing a bendable section with controlled flexibility. This parameter change allows the structure to adapt its stiffness - rigid when engaged for precision, flexible during installation for ease of mounting. The flexibility parameter is specifically designed to control the installation and extraction forces within acceptable ranges.
2Manufacturing precision
If manufacturing tolerances are reduced to eliminate lash, then manufacturing precision is improved, but production cost and complexity increase
Solution Approach 1:
Instead of controlling dimensional parameters through tight tolerances, the patent changes the physical parameter of the arm to be flexible. This flexibility compensates for dimensional variations and manufacturing tolerances in other components, eliminating lash without requiring complex tolerance control. The flexible arm absorbs the variations through its bending capability.
Solution Approach 2:
The flexible arm acts as an intermediary element between the terminal connector and the mounting fixture. It mediates the connection by accommodating dimensional variations and misalignments through controlled bending, thereby eliminating lash and the need for tight tolerances in other components.
3Reliability
If terminal connectors are made rigid to maintain connection stability, then reliability is improved, but installation becomes difficult due to high forces required
Solution Approach 1:
The terminal connector uses a dynamic flexible arm that transitions from a flexible state during installation to a stable engaged state. During installation, the arm bends easily to accommodate alignment variations, making installation simple. Once engaged, the arm maintains stable connection, ensuring reliability. The same structure provides both ease of installation and connection stability.
Solution Approach 2:
The arm is segmented into a flexible portion and a rigid portion. The flexible portion enables easy installation by bending to accommodate misalignments, while the rigid portion maintains connection stability when engaged. This segmentation allows the terminal connector to exhibit different mechanical properties at different stages of operation.
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
This solution reduces the forces required for installation and extraction while minimizing lash and improving the accuracy of motion transmission by allowing for controlled flexure and alignment of the terminal connectors with mounting fixtures.
Implementation Method 1
an isolator material... to reduce lash and accommodate manufacturing tolerances, allowing for adjustable connections
Implementation Method 2
swivel tube... to reduce lash and accommodate manufacturing tolerances, allowing for adjustable connections
Data Source
AI summary
Novel terminal connectors or fittings and terminal connector assemblies using such novel terminal connectors are disclosed. The terminal connector assemblies have uses which include, for example, on load- or motion-transmitting cable assemblies, e.g., for aircraft, automotive, and marine vehicle applications. Certain exemplary embodiments of the terminal connectors and terminal connector assemblies have features that, either alone or in combination, provide desirable characteristics such as, e.g., reduced lash or vibration in such cable assemblies. Such features include, but are not limited to groove(s) disposed in an arm of the fitting, tab member(s) extending from an arm of the terminal connector, projection(s) positioned on an arm of the fitting, etc.