Handheld Wire Insertion Funnel for Damage-Free Contact Loading
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Solution Overview
Problem
Inserting conductive wires into electrical contacts is challenging due to alignment issues, often resulting in wire damage or increased time requirements, especially in manual operations like replacing connectors in vehicle or airplane engine power systems.
Innovation Solution
A handheld wire insertion tool with a receiving portion, funnel portion, and securing member that guides and secures conductive wires into the electrical contact, ensuring proper alignment and preventing damage through a radial interference fit and tapered funnel design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual wire insertion is performed without guidance tools, then operational flexibility is maintained, but wire alignment precision deteriorates causing splay and damage
Solution Approach 1:
The patent introduces a guiding tool as an intermediary device between the operator and the wire insertion process. This tool includes a receiving portion for the electrical contact and a funnel portion that guides the wires, acting as a mediator to achieve precise alignment without requiring complex manual dexterity
Solution Approach 2:
The guiding tool appears to be a simple, easily manufactured device that can be readily replaced if needed. The design uses basic geometric components (receiving portion, funnel portion, securing member) that can be produced economically and disposed of or replaced without significant cost or complexity
2Productivity
If wires are forced into misaligned contacts, then insertion speed is maintained, but wire damage increases
Solution Approach 1:
The funnel portion of the guiding tool performs preliminary alignment of the wires before they enter the electrical contact. By pre-positioning and guiding the wires through the tapered funnel, the alignment is established before insertion, eliminating the need for forceful insertion and preventing wire damage
Solution Approach 2:
The funnel portion changes the geometric parameters of wire insertion by providing a tapered guide path. This geometric parameter change (from random orientation to aligned orientation through the funnel angle) enables smooth insertion without force, maintaining both speed and wire integrity
3Reliability
If extraction and re-insertion of splayed wires is performed, then wire damage is avoided, but operational time increases
Solution Approach 1:
The guiding tool performs preliminary alignment and guidance throughout the insertion process, ensuring wires are correctly positioned from the start. This preliminary action prevents the need for extraction and re-insertion operations, eliminating time loss while maintaining wire integrity
Solution Approach 2:
The funnel portion provides continuous visual and physical feedback during insertion, allowing the operator to see and feel the wires being guided into proper alignment. This feedback mechanism enables real-time correction and ensures correct insertion on the first attempt, avoiding time-consuming rework
Data Source
Figure 1A
Figure 1B~1C
Figure 2A~2B
AI summary
A handheld wire insertion tool for inserting conductive wires of a cable into an electrical contact, the tool comprising: a receiving portion configured to receive an electrical contact; a funnel portion configured to guide free ends of conductive wires of a cable into the electrical contact when the contact is located in the receiving portion; and a securing member configured to secure the funnel portion relative to the electrical contact located in the receiving portion.