Wire Insertion Funnel for Precise Contact Alignment
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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 hand-operated scenarios like replacing connectors in vehicle or airplane engine power systems.
Innovation Solution
A handheld wire insertion tool with a receiving portion, a funnel portion, and a securing member that guides and secures the 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
1Ease of operation
If conductive wires are inserted by hand into the electrical contact, then the operation can be performed manually, but the wires may splay out and become damaged or require re-insertion
Solution Approach 1:
The patent introduces a handheld insertion tool as an intermediary device between the operator and the wires. The tool includes a receiving portion that holds the electrical contact, a funnel portion that guides the wires, and a securing member that clamps the contact. This intermediary tool prevents wire splaying and damage while maintaining manual operation capability.
Solution Approach 2:
The tool performs preliminary actions by securing the electrical contact in the receiving portion and positioning the funnel before wire insertion. The securing member clamps the contact in place, and the funnel is positioned to guide wires, ensuring proper alignment is established before the actual wire insertion occurs.
2Device complexity
If conductive wires are inserted without guidance, then the insertion process is simple, but the wires may splay out and require extraction and re-insertion
Solution Approach 1:
The insertion tool is segmented into three functional portions: a receiving portion for holding the electrical contact, a funnel portion for guiding wires, and a securing member for clamping. This segmentation allows each component to perform its specific function efficiently, preventing wire splaying without requiring a completely complex device structure.
Solution Approach 2:
The tool components are nested within each other: the electrical contact is received in the receiving portion, the funnel is positioned within the receiving portion to guide wires into the contact, and the securing member encompasses both to provide clamping force. This nested arrangement achieves effective wire guidance and alignment without excessive device complexity.
3Device complexity
If the funnel portion is not secured relative to the electrical contact, then the tool structure is simpler, but proper alignment cannot be maintained during wire insertion
Solution Approach 1:
The funnel portion has a tapered, curved geometry that naturally guides wires toward the center of the electrical contact. This curved shape provides inherent alignment guidance, reducing the complexity of the securing mechanism while maintaining precise wire alignment during insertion.
Data Source
AI summary
A handheld wire insertion tool for inserting conductive wires of a cable into an electrical contact. The tool includes: 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.