Wire Insertion Tool With Gripper for Consistent Pull-Testing
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Solution Overview
Problem
Manual installation and testing of electrical wires in push-in connectors leads to hand fatigue and potential improper connections, particularly in industries like aircraft manufacturing.
Innovation Solution
A tool with a frame, handle, and gripper mechanism that allows for automated insertion and pull-testing of wires, ensuring proper seating and retention in connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual wire installation and pull-testing is performed repeatedly, then flexibility and simplicity are maintained, but hand fatigue increases and connection quality may deteriorate
Solution Approach 1:
The patent introduces a tool as an intermediary device between the operator and the wire connection process. The tool includes a gripper that clamps onto the wire and a pull-testing mechanism that applies controlled force, mediating the interaction between manual operation and connection validation to ensure consistent results without direct hand fatigue
Solution Approach 2:
The tool is designed to perform both wire insertion and pull-testing functions in a self-contained manner. The gripper automatically clamps the wire during insertion, and the pull-testing mechanism independently validates the connection, allowing the tool to serve itself through integrated functions rather than requiring separate manual operations
2Reliability
If automated tool with gripper mechanism is used for wire insertion and pull-testing, then connection quality and consistency are improved, but device complexity increases
Solution Approach 1:
The patent combines wire insertion and pull-testing functions into a single integrated tool. The gripper mechanism serves dual purposes: clamping the wire during insertion and applying pull-force during testing. This merging of functions reduces the need for separate tools and minimizes overall device complexity while maintaining reliability
Solution Approach 2:
The tool is designed with multi-functionality, where the same gripper and frame structure perform both insertion and pull-testing operations. The receiver and insertion tip are configured to handle both functions universally, eliminating the need for tool changes or additional specialized components
3Device complexity
If manual wire insertion is performed without clamping mechanism, then device complexity is reduced, but wire retention and connection reliability deteriorate
Solution Approach 1:
The gripper acts as an intermediary clamping mechanism between the insertion tip and the wire. It provides precise control over wire positioning and retention during insertion, ensuring manufacturing precision without requiring the entire tool structure to be complex
Data Source
AI summary
A tool for inserting and pull-testing a wire includes a frame. The frame includes a handle and a working end. The tool includes a receiver. The received is disposed at the working end. The receiver is configured to hold an insertion tip. A wire passes through the insertion tip. The tool includes a gripper. The gripper is coupled to the frame. The gripper is selectively movable between an engaged position and a disengaged position. In the engaged position, the gripper clamps the wire to prevent movement of the frame relative to the wire. In the disengaged position, the gripper unclamps the wire to enable movement of the frame relative to the wire.