Wire Insertion Tool With Integrated Pull-Test Gripper
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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, especially in industries like the aircraft industry, where frequent installations are required.
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, reducing user fatigue and improving connection reliability.
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 reliability decreases
Solution Approach 1:
The tool performs self-testing by automatically conducting pull-tests on the wire connection after insertion. The gripper mechanism clamps the wire and applies pull force to verify connection integrity, allowing the system to self-validate without requiring separate manual testing operations.
Solution Approach 2:
The patent replaces manual mechanical operations with an automated tool system. The gripper mechanism and frame structure substitute for human hand operations, performing both insertion and pull-testing functions mechanically through coordinated movement of the gripper between engaged and disengaged positions.
2Adaptability or versatility
If manual wire installation is performed a large number of times, then operational flexibility is maintained, but hand fatigue increases and installation quality deteriorates
Solution Approach 1:
The tool combines multiple functions into a single device: wire insertion, wire clamping, and pull-testing. The gripper can both clamp the wire during insertion and perform pull-tests afterward, making the tool universal for both installation and validation operations.
Solution Approach 2:
The patent merges the insertion tool and testing tool into a single integrated device. The frame, gripper, and wire clamping mechanism are combined to perform both installation and quality verification in one tool, eliminating the need for separate manual operations.
3Reliability
If automated tool is used for wire insertion and pull-testing, then connection reliability and productivity are improved, but device complexity increases
Solution Approach 1:
The tool is divided into distinct functional segments: the frame provides structural support, the gripper performs clamping and pulling operations, and the insertion tip handles wire insertion. This segmentation allows each component to be optimized for its specific function while maintaining overall system reliability.
Solution Approach 2:
The gripper is designed with movable parts that transition between engaged and disengaged positions. This dynamic capability allows the same component to perform different functions (clamping during insertion, pulling during testing) without requiring completely separate mechanisms for each operation.
Data Source
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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.