Self-aligning mechanical mounting and electrical connection system for electronic modules with features for robotic assembly

Abstract

A self-aligning mechanical mounting and electrical connection system for an electronic module includes a mechanical mounting assembly configured to be integrated into or attached to a base rack and defining a mounting connection position assurance (CPA) feature for self-aligning and securing the electronic module therein, and an electrical connection assembly configured to be integrated into or attached to the mechanical mounting assembly and including a modular electrical connector that (i) is electrically connected to an electrical backbone cable and (ii) defines a connector CPA feature for self-aligning the modular electrical connector with a corresponding electrical connector integrated into or attached to the electronic module when the electronic module is secured in the mechanical mounting assembly.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Application No. 62 / 956,884, filed January 3, 2020. The disclosure of this application is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to automotive electrical systems, and more specifically, to a self-aligned mechanical mounting and electrical connection system for electronic modules having features for robotic components. Background Technology

[0004] Electrical systems may include multiple electronic modules (e.g., controllers or control units), each configured to monitor and control a corresponding set of devices. For example, multiple electronic modules may be installed in different sections or areas relative to the chassis (e.g., underframe or floor rack) of an electrified vehicle. Autonomous installation of these electronic modules by a robotic installer can be preferable to manual installation due to increased speed and reduced costs. However, installing electronic modules typically requires connecting them to a large number of cables, which is both complex and time-consuming. For example, these cables may need to connect the electronic module not only to its corresponding monitored / controlled devices but also to at least some of other electronic modules (e.g., other electronic modules in the electrified vehicle). Additionally, these electronic modules may need to be physically secured to minimize or eliminate potential damage due to physical vibration, while also dissipating excessive heat. Therefore, while conventional electronic modules and their installation methods function well for their intended purpose, there are opportunities for improvement in the related technology.

[0005] The background description provided herein is for the purpose of presenting the overall context of this disclosure. The presently mentioned work of the inventors, and aspects described at the time of filing as prior art, to the extent described in this background section, are neither expressly nor implicitly acknowledged as prior art to this disclosure. Summary of the Invention

[0006] According to one aspect of this disclosure, a self-aligning mechanical mounting and electrical connection system for an electronic module is presented. In one exemplary implementation, the system includes: a mechanical mounting assembly configured to be integrated into or attached to a base frame and defining a mounting connection position guarantee (CPA) feature for self-aligning and securing the electronic module therein; and an electrical connection assembly configured to be integrated into or attached to the mechanical mounting assembly and including a modular electrical connector (i) electrically connected to an electrical backbone cable and (ii) defining a connector CPA feature for self-aligning the modular electrical connector with a corresponding electrical connector integrated into or attached to the electronic module when the electronic module is secured in the mechanical mounting assembly.

[0007] In some implementations, the base frame is the underframe or floor frame of the electrified vehicle, and the electronic module is configured to be vertically mounted by lowering the electronic module into the mechanical mounting assembly until the electronic module is secured in the mechanical mounting assembly by the mounting CPA feature. In some implementations, the electrical backbone cable includes at least power cables and data cables, and wherein the electrical backbone cable is a substantially flat cable extending along the underframe or floor frame of the electrified vehicle.

[0008] In some implementations, the system includes multiple electrical backbones, and at least a portion of these backbones are directly connected to each other via a bypass system, allowing power or data circuitry not required by the electronic module to bypass it. In some implementations, each modular electrical connector is positioned upwards, such that the corresponding connector integrated into or attached to the electronic module can be mounted perpendicularly to the electronic module.

[0009] In some implementations, the mechanical mounting assembly is formed of sheet metal and integrated into the sheet metal portion of the underframe or floor rack of the electrified vehicle. In some implementations, the system further includes a set of heat transfer devices configured to transfer heat from the electronic module. In some implementations, the set of heat transfer devices is one or more heat transfer pads that transfer heat from the electronic module to the sheet metal portion of the underframe or floor rack of the electrified vehicle.

[0010] In some implementations, the electronic module defines a set of one or more robot mounting features configured to interact via the end effector of the robot mounter to lower the electronic module into the mechanical mounting assembly until the electronic module is secured in the mechanical mounting assembly by the mounting CPA feature. In some implementations, the electronic module is removable or configured to be released from the mechanical mounting assembly using special physical tools controlled by a human technician or the robot mounter.

[0011] According to another aspect of this disclosure, a method for mechanically mounting, aligning, and electrically connecting an electronic module is presented. In one exemplary implementation, the method includes: providing a mechanical mounting assembly configured to be integrated into or attached to a base frame and defining mounting CPA features for self-aligning and securing the electronic module therein; and providing an electrical connection assembly configured to be integrated into or attached to the mechanical mounting assembly and including a modular electrical connector (i) electrically connected to an electrical backbone cable and (ii) defining connector CPA features for self-aligning the modular electrical connector with a corresponding electrical connector integrated into or attached to the electronic module when the electronic module is secured in the mechanical mounting assembly.

[0012] In some implementations, the base frame is the underframe or floor frame of the electrified vehicle, and the method further includes vertically mounting the electronic module by lowering it into the mechanical mounting assembly until the electronic module is secured in the mechanical mounting assembly by the mounting CPA feature. In some implementations, the electrical backbone cable includes at least power cables and data cables, and wherein the electrical backbone cable is a substantially flat cable extending along the underframe or floor frame of the electrified vehicle.

[0013] In some implementations, the electrical connection assembly includes a plurality of electrical backbone cables, wherein at least a portion of the plurality of electrical backbone cables are directly connected to each other via a bypass system, allowing power or data circuitry not required by the electronic module to bypass the electronic module. In some implementations, each modular electrical connector is positioned upwards, such that the corresponding electrical connector integrated into or attached to the electronic module can be mounted perpendicularly to the electronic module.

[0014] In some implementations, the mechanical mounting assembly is formed of sheet metal and integrated into the sheet metal portion of the underframe or floor rack of the electrified vehicle. In some implementations, the method further includes providing a set of heat transfer devices configured to transfer heat from the electronic module, wherein the set of heat transfer devices is one or more heat transfer pads that transfer heat from the electronic module to the sheet metal portion of the underframe or floor rack of the electrified vehicle.

[0015] In some implementations, the electronic module defines a set of one or more robot mounting features, and further includes interacting with the set of one or more robot mounting features via an end effector of a robot mounter, and lowering the electronic module into the mechanical mounting assembly via the robot mounter until the electronic module is secured in the mechanical mounting assembly by the mounting CPA feature. In some implementations, the method further includes releasing the electronic module from the mechanical mounting assembly using special physical tools by a human technician or the robot mounter, so that the electronic module can be removed.

[0016] According to another aspect of this disclosure, a self-aligning mechanical mounting and electrical connection system for an electronic module is presented. In one exemplary implementation, the system includes: a mechanical mounting assembly for integration into or attachment to a base frame and defining mounting CPA features for self-aligning and securing the electronic module therein; and an electrical connection assembly for integration into or attachment to the mechanical mounting assembly and including a modular electrical connector assembly for (i) electrical connection to an electrical backbone cable assembly and (ii) defining connector CPA feature devices for self-aligning the modular electrical connector assembly with a corresponding electrical connector assembly integrated into or attached to the electronic module when the electronic module is secured in the mechanical mounting assembly.

[0017] According to another aspect of this disclosure, a substantially flat electrical backbone cable is presented. In one exemplary implementation, the substantially flat electrical backbone cable includes: a substantially flat power cable portion including a first set of dielectric insulation layers; a first shielding layer, the first shielding layer being surrounded by at least some of the first set of dielectric insulation layers except for exposed portions thereof; a grounding layer, the grounding layer being surrounded by at least some of the first set of dielectric insulation layers except for exposed portions thereof; and a power bus layer disposed between the first shielding layer and the grounding layer, and the power bus layer being surrounded by the first set of dielectric insulation layers except for exposed portions thereof. The second shielding layer is surrounded by at least some of the second set of dielectric insulating layers, and includes a substantially flat data cable portion that is substantially parallel to and close to the substantially flat power cable portion; a second shielding layer that is surrounded by at least some of the second set of dielectric insulating layers, except for an exposed portion of the second shielding layer; and a set of data trace layers that are substantially parallel to each other and disposed between the second shielding layers, and are surrounded by at least some of the second set of dielectric insulating layers, except for an exposed set of data trace layers.

[0018] In some implementations, at least one of the following two methods is implemented: (i) the exposed first shielding layer portion, the exposed ground layer portion, and the exposed power bus layer portion are arranged in a sequential, vertically stepped, or interleaved configuration; and (ii) the exposed second shielding layer portion and the group of exposed data trace layer portions are arranged in a sequential, vertically stepped, or interleaved configuration. In some implementations, the exposed first shielding layer portion, the exposed ground layer portion, and the exposed power bus layer portion are arranged in a sequential, vertically stepped, or interleaved configuration, and the exposed second shielding layer portion and the group of exposed data trace layer portions are arranged in a sequential, vertically stepped, or interleaved configuration.

[0019] In some implementations, the electrical backbone cable further includes at least one U-shaped electrical connector that electrically contacts each of the exposed first shielding portion, the exposed second shielding portion, the exposed grounding portion, the exposed power bus layer portion, and the exposed data trace layer portion. In some implementations, the wide bottom portion of each U-shaped electrical connector electrically contacts each of the exposed first shielding portion, the exposed second shielding portion, the exposed grounding portion, the exposed power bus layer portion, and the exposed data trace layer portion. In some implementations, the electrical backbone cable further includes a modular electrical connector having the U-shaped electrical connector integrated therein or having the U-shaped electrical connector electrically connected thereto. In some implementations, the modular electrical connector is configured to electrically connect to a corresponding electrical connector of an electronic module.

[0020] In some implementations, the electronic module is a controller or control unit of the electrified vehicle. In some implementations, the electronic module is configured to be physically mounted to the underframe or floor rack of the electrified vehicle, and the electrical backbone cable is configured to be mounted along the underframe or floor rack of the electrified vehicle. In some implementations, the opposite end of the electrical backbone cable, opposite to the modular electrical connector, is electrically connected to another modular electrical connector, which is configured to be electrically connected to another corresponding electrical connector of another electronic module of the electrified vehicle.

[0021] Further applicability of this disclosure will become apparent from the detailed description provided below. It should be understood that the specific embodiments and examples are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description

[0022] This disclosure will be more fully understood through detailed description and the accompanying drawings, in which:

[0023] Figures 1A-1B The illustration shows a view of an example mechanical mounting assembly for a self-aligned mechanical mounting and electrical connection system for an electronic module according to some implementations of this disclosure;

[0024] Figures 2A-2B The diagram illustrates some implementations of this disclosure, including... Figures 1A-1B A view of an example component of a self-aligning mechanical mounting and electrical connection system for electronic modules; and

[0025] Figures 3A-3B The diagram illustrates electronic modules and some implementations of this disclosure. Figures 2A-2BTop-down installation of self-aligning mechanical mounting and electrical connection systems;

[0026] Figures 4A-4B The diagram illustrates some implementations of this disclosure for use with Figures 2A-2B Example heat transfer equipment with a self-aligning mechanical mounting and electrical connection system;

[0027] Figures 5A-5C The diagram illustrates some implementations of this disclosure for use with Figures 2A-2B Example electronic module bypass system of self-aligning mechanical mounting and electrical connection system; and

[0028] Figures 6A-6B The illustration shows an example top-down construction or installation of an electrical backbone cable for connection to an electronic module via a self-aligning mechanical mounting and electrical connection system, according to some embodiments of the present disclosure. Detailed Implementation

[0029] Now for reference Figures 1A-1B The illustration shows an example configuration of a mechanical mounting assembly 100 for a self-aligned mechanical mounting and electrical connection system for an electronic module (not shown) according to the principles of this disclosure. The mechanical mounting assembly 100 defines a base plate or base member 104 configured to be physically attached to a base frame. In one exemplary implementation, the base frame is the underframe or floor frame of an electrified vehicle (e.g., an autonomous vehicle), which may be formed of sheet metal (steel, aluminum, etc.). In one exemplary implementation, the mechanical mounting assembly 100 is formed of sheet metal of the same or similar type as the underframe or floor frame of an electrified vehicle, such that the mechanical mounting assembly 100 can be integrally formed with the base frame. However, it should be understood that the mechanical mounting assembly 100 may also be physically attached to the underframe or floor frame (e.g., using an attachment device 108 defined in the base member 104), and the mechanical mounting assembly 100 may also be formed of a different material (e.g., injection-molded plastic). Mechanical mounting assembly 100 defines a first set and a second set of mounting connection position guarantee (CPA) features 112a, 112b. The first set of mounting CPA features 112a is shown as a spring clip configured to engage with the side surface of an electronic module (not shown). The second set of mounting CPA features 112b is shown as a spring clip configured to provide upward resistance on the bottom surface of the electronic module (not shown). Although spring clips are specifically shown, it should be understood that any suitable CPA feature for physically securing the electronic module (not shown) can be utilized.

[0030] Now for reference Figures 2A-2BReferring again to the preceding figures, the mechanical mounting assembly 100 further defines a set of connector receptacles 116a, 116b, and a first and second set of connector CPA features 120a, 120b for each connector receptacle 116a, 116b. Although the mechanical mounting assembly 100 and the two connector receptacles 116a, 116b are shown in a rectangular shape, it should be understood that other electronic module shapes or configurations, as well as other configurations and / or numbers of connector receptacles, can be accommodated. The first set of connector CPA features 120a is shown as a spring clip configured to engage with the side surfaces of modular electrical connectors 212a, 212b, which are electrically connected to corresponding electrical backbone cables 208a, 208b to form corresponding electrical connection assemblies 204 (specifically referenced and labeled 204a, 204b). The combination of mechanical mounting assembly 100 and one or more electrical connection assemblies 204 collectively forms an example of a self-aligning mechanical mounting and electrical connection system according to some implementations of this disclosure, hereinafter referred to as 200. These electrical backbone cables 208a, 208b are substantially flat cables configured to transmit at least power and data (e.g., transmission to / from other electronic modules of the electrified vehicle). A second set of connector CPA features 112b is also shown as spring clips configured to provide upward resistance on the bottom surface of the modular electrical connectors 212a, 212b. When secured in connector sockets 116a, 116b, the modular electrical connectors 212a, 212b will be able to electrically connect to an electronic module (not shown). It should be understood that when secured in connector sockets 116a, 116b, the modular electrical connectors 212a, 212b can still have some degree of mobility to allow for self-alignment with the corresponding electrical connector of the electronic module (not shown), which will now be described in more detail.

[0031] Now for reference Figures 3A-3BReferring again to the preceding figures, an example top-down mounting of an electronic module 300 with a self-aligned mechanical mounting and electrical connection system 200 according to some implementations of this disclosure is illustrated. The electronic module 300 includes a housing 304 housing an electronic system (not shown), which may include one or more processors, memories, etc. Two electrical connectors 312a and 312b are defined in the bottom surface 308 of the housing 304, corresponding to modular electrical connectors 212a and 212b, respectively. Robot mounting features 320 for top-down robotic mounting of the electronic module 300 are defined in the side surface 316 of the housing 304. As shown, these robot mounting features are two square-shaped protrusions defining a slot between them, which can be engaged and temporarily secured to the end connector of a robot mounter (not shown). Although a side slot robot mounting feature is shown, it should be understood that any suitable robot mounting feature can be integrated into or at least temporarily attached to housing 304, allowing the end effector of the robot mounter (not shown) to have movable and secure control of the electronic module 300 to mount the electronic module 300 to the electrical connection system 200. In some implementations, one or more identifiers can be defined in housing 304 to assist in robot mounting. As used herein, the term “identifier” refers to any mark that can be identified by the robot mounter (not shown), including but not limited to barcodes, quick response (QR) codes, strings of numbers, strings of letters, or strings of alphanumeric characters, or symbols / shapes. As an example only, the identifiers(s) can be laser-etched or engraved on housing 304. As shown, electronic module 300 includes another rectangular connector 324 on one of its side surfaces 316. Although any modular electrical connector for electrical connection to electrical connection system 200 is not shown, it will be understood that electrical connection system 200 may include another suitable modular electrical connector that can be electrically connected to connector 324 during mounting. To give just one example, the connector 324 can be used to connect the electronic module 300 to the corresponding electrical equipment it monitors / controls (e.g., radar, lidar, traction motor, etc.).

[0032] Now for reference Figures 4A-4BReferring again to the preceding figures, example heat transfer devices 400 for a self-aligned mechanical mounting and electrical connection system 200 according to some implementations of this disclosure are illustrated. Each of these heat transfer devices 400 is configured to transfer or dissipate heat energy from an electronic module 300 and / or one or more electrical connection components 204 (e.g., modular electrical connectors 212a, 212b). These heat transfer devices 400 can be formed of any suitable material configured to transfer heat energy through them. By operating as a heat remover or radiator, these heat transfer devices 400 are able to prevent potential damage to any component (e.g., electronic module 300) due to excessive heat energy. This can be particularly useful in autonomous electrified vehicle applications, where large amounts of power and data continuously flow through the system. Figure 4A In the heat transfer device, two components, 400a and 400b, are visible. When the electronic module 300 is installed in the electrical connection system 200, the heat transfer device is associated with the electronic module 300. Figure 4B In the diagram, the first two heat transfer devices 400a and 400b remain visible, as are two additional heat transfer devices 400c and 400d, respectively associated with modular electrical connectors 212a and 212b. While these heat transfer devices 400a, 400b, 400c, and 400d (collectively referred to as heat transfer devices 400) are shown as heat transfer pads 400a and 400b recessed into corresponding notches or holes defined in the base member 104 of the mechanical mounting assembly 100, it will be understood that other types and / or configurations for the heat transfer devices 400 (active or passive) can be utilized. It will also be understood that more complex heat transfer systems can be utilized, or additional component portions not shown can be used. For example, this could include only active cooling or heat transfer components, such as air-based cooling components (e.g., fans or heat sinks) and / or liquid-based cooling components (water jackets, pumps, condensers / evaporators, refrigerant piping, etc.).

[0033] Now for reference Figures 5A-5C Referring again to the preceding figures, example electronic module bypass systems 500 for a self-aligned mechanical mounting and electrical connection system 200 according to some implementations of this disclosure are illustrated. Each of these electronic module bypass systems 500 effectively bypasses the electronic module 300 by utilizing at least some portions of the electrical backbone cables 208a, 208b. To cite just one example, some electronic modules may not require all the power and / or data carried along certain electrical backbone cables. Figure 5AThe figure illustrates a first example electronic module bypass system 500a. As shown, the electronic module bypass system 500a is a substantially flat cable that extends along the base member 104 and directly connects at least a portion of the modular electrical connectors 212a, 212b, thereby bypassing the electronic module 300 during installation. The substantially flat shape of the electronic module bypass system 500a does not affect the installation of the electronic module 300 into the electrical connection system 200. Figures 5B-5C Two other example electronic module bypass systems 500b and 500c are illustrated, which are set or arranged outside the mechanical mounting assembly 100. Figure 5B In this configuration, the electronic module bypass system 500b is a basic flat cable that directly connects at least a portion of the electrical backbone cables 208a and 208b (thus bypassing both the electronic module 300 and the modular electrical connectors 212a and 212b). Figure 5C In this system, the electronic module bypass system 500c is a basic flat cable that directly connects the modular electrical connector 212a to the electrical backbone cable 208b (thus bypassing both the electronic module 300 and the modular electrical connector 212b). It should be understood that this can be achieved using... Figure 5C The reverse configuration. It will also be understood that these electronic module bypass systems 500 may be round (e.g., coaxial) cables instead of substantially flat ribbon cables, although substantially flat ribbon cables may be preferred for encapsulation reasons (e.g., folding flat during transport and before installation).

[0034] Now for reference Figures 6A-6B Referring again to the preceding figures, an example top-down configuration or mounting is illustrated for a portion 600 of an electrical backbone cable 208 connected to an electronic module 300 via a self-aligned mechanical mounting and electrical connection system 200, according to some implementations of this disclosure. Figure 6A In this configuration, a generally flat shielding layer and a grounding layer 608 are laid out, with a generally flat power bus layer laid between them. For example, these layers 604, 608 can be laid out on the surface in a top-down manner, such that the layers are stacked together. Layers 604, 608 and(multiple) dielectric insulation layers 612 can also be collectively referred to as the power cable portion of the electrical backbone cable 208. Similarly, in Figure 6AIn this configuration, a generally flat data shielding layer 620 is laid, with generally flat data trace layers 616 laid between them. For example, these layers 616, 620 can be laid on the same surface in a top-down manner, such that these layers are stacked together and positioned very close to other stacked layers 604, 408. Layers 612, 616, and 620 can also be collectively referred to as the data cable portion of the electrical backbone cable 208. Furthermore, the ends of these layers 604, 608 and 612, 216 can terminate at different lengths to provide a top-down or vertical connection point for each layer 604, 608 and 612, 616, which will be described in more detail below. This is also described herein as a sequential, vertical stepped, or staggered configuration. In other words, the bottom layer of each stack extends the furthest, and each layer above that bottom layer extends a shorter distance, but each extends a longer distance than the layer above it. Each layer 604, 608, 616, 620 can also be fully insulated by corresponding dielectric insulation layers(s) 612. This top-down layering of the portion 600 forming the electrical backbone cable 208 provides a substantially flat electrical backbone cable 208, which saves packaging space while providing optimal electrical connectivity. Figure 6B The diagram illustrates top-down electrical connections to the exposed portions of layers 604, 608, 616, and 620. As shown, U-shaped electrical connectors 624, 628, 632, and 636 make vertical contacts to layers 604, 608, 616, and 620, respectively, with the wide bottom portion of each U-shaped electrical connector 624, 628, 632, and 636 making flat contacts to each corresponding layer 604, 608, 616, and 620 to provide the optimal electrical connection as described above. For example, each of these U-shaped electrical connectors 624, 628, 632, and 636 may be integrated into or electrically connected to a corresponding one of modular electrical connectors 212a or 212b. It will also be understood that the electrical backbone cable 208 may also include other wiring, such as one or more round coaxial cables extending along the top of the flat layers as described above.

[0035] While this document specifically describes and illustrates particular vertical or top-down mounting of electronic modules at the underframe or floor rack of an electrified vehicle, it should be understood that, based on the principles of this disclosure, self-aligning mechanical mounting and electrical connection systems can have a variety of other applications. Firstly, other mounting and installation configurations (side / lateral, bottom-up, angled, etc.) can be utilized. One example alternative implementation is at the vertical vehicle firewall (i.e., between the vehicle cabin and the powertrain compartment), where cables are typically passed manually by a person through a small opening. Using the system of this disclosure, the system can be provided on one side of the opening or integrated therein, and then a robotic or human installer can install the corresponding electronic module there in a single operation. Other non-limiting examples of vehicle applications include door electrical systems and corresponding electronic modules, vehicle dashboard / infotainment system electrical systems and corresponding electronic modules, and vehicle trunk electrical systems and corresponding electronic modules. Furthermore, it will be understood that a single system can accept multiple electronic modules that can be mated together or operated individually. For example, a single system can accept corresponding electronic sub-modules on two opposite sides, thereby electrically connecting the two systems (e.g., the two electronic sub-modules can operate as a single module).

[0036] Example embodiments are provided so that this disclosure will be thorough and will fully convey the scope of protection to those skilled in the art. Numerous specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of embodiments of this disclosure. It will be apparent to those skilled in the art that the example embodiments may be embodied in many different forms without requiring the specific details, and should not be construed as limiting the scope of this disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known techniques are not described in detail.

[0037] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to be limiting. As used herein, the singular forms “a,” “an,” and “the” may also be intended to include the plural forms unless the context clearly indicates otherwise. The term “and / or” includes any and all combinations of one or more of the associated listed items. The terms “comprises,” “comprising,” “including,” and “having” are inclusive and therefore specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Unless expressly identified as an order of execution, the method steps, processes, and operations described herein should not be construed as requiring them to be performed in the specific order discussed or shown. It should also be understood that additional or alternative steps may be employed.

[0038] While the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or portions, these elements, components, regions, layers, and / or portions should not be limited by these terms. These terms are used only to distinguish one element, component, region, layer, or portion from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms used herein do not imply order or sequence. Therefore, the first element, component, region, layer, or portion discussed below may be referred to as a second element, component, region, layer, or portion without departing from the teachings of the exemplary embodiments.

[0039] As used herein, the term "electronic module" may refer to, be part of, or include: application-specific integrated circuits (ASICs); electronic circuits; combinational logic circuits; field-programmable gate arrays (FPGAs); processors or distributed networks of processors (shared, dedicated, or grouped) and storage in networked clusters or data centers that execute code or processes; other suitable components that provide the described functionality; or combinations or all of the foregoing, such as in a system-on-a-chip. The term "module" may also include memory (shared, dedicated, or grouped) that stores code executed by one or more processors.

[0040] As used above, the term "code" can include software, firmware, bytecode, and / or microcode, and can refer to programs, routines, functions, classes, and / or objects. As used above, the term "shared" means that some or all of the code from multiple modules can be executed using a single (shared) processor. Additionally, some or all of the code from multiple modules can be stored in a single (shared) memory. As used above, the term "grouped" means that some or all of the code from a single module can be executed using a group of processors. Additionally, a set of memory can be used to store some or all of the code from a single module.

[0041] The techniques described herein can be implemented by one or more computer programs executed by one or more processors. The computer program includes computer-executable instructions stored on a non-transient tangible computer-readable medium. The computer program may also include stored data. Non-limiting examples of non-transient tangible computer-readable media are non-volatile memory, magnetic memory, and optical memory.

[0042] Some parts of the above description present the techniques described herein based on the algorithms and symbolic representations of information operations. These algorithmic descriptions and representations are means by which those skilled in the art of data processing effectively communicate the substance of their work to others skilled in the art. Although these operations are described functionally or logically, they should be understood as being implemented by computer programs. Furthermore, referring to the arrangement of these operations as modules or naming them by function has repeatedly proven convenient without loss of generality.

[0043] Unless otherwise specified, as is apparent from the foregoing discussion, it should be understood that the discussion throughout the specification using terms such as “processing,” “calculating,” “calculating,” “determining,” and “displaying” refers to the actions and processes of a computer system or similar electronic computing device that manipulate and transform data represented as physical (e.g., electronic) quantities within computer system memory and registers or other such information storage, transmission, or display devices.

[0044] Certain aspects of the described technology include processing steps and instructions described herein in algorithmic form. It should be noted that the described processing steps and instructions may be embodied in software, firmware, or hardware, and when embodied in software, may be downloaded to reside on and be operated from different platforms used by a real-time network operating system.

[0045] This disclosure also relates to means for performing the operations described herein. Such means may be specifically configured for a desired purpose, or it may comprise a general-purpose computer selectively activated or reconfigured by a computer program stored on a computer-readable medium accessible to the computer. Such computer programs may be stored in tangible computer-readable storage media, such as, but not limited to, any type of disk including floppy disks, optical disks, CD-ROMs, magneto-optical disks, read-only memory (ROM), random access memory (RAM), EPROM, EEPROM, magnetic cards or optical cards, application-specific integrated circuits (ASICs), or any type of medium suitable for storing electronic instructions, each coupled to a computer system bus. Furthermore, a computer referred to herein may include a single processor or may be an architecture employing multiple processors to enhance computing power.

[0046] The algorithms and operations presented herein are not inherently related to any particular computer or other device. Various general-purpose systems may also be used with programs based on the teachings herein, or it may prove convenient to construct more specialized devices to perform the required method steps. The necessary structures for various such systems, as well as equivalent variations, will be apparent to those skilled in the art. Furthermore, this disclosure does not refer to any particular programming language. It should be understood that the teachings of this disclosure as described herein can be implemented using various programming languages, and any references to a particular language are provided for the purpose of disclosing implementations and best practices of the invention.

[0047] This disclosure is well-suited for various computer network systems on numerous topologies. Within this field, the configuration and management of large networks involves storage devices and computers communicatively coupled to different computers and storage devices via networks such as the Internet.

[0048] The foregoing description of embodiments has been provided for purposes of illustration and description. This description is not intended to be exhaustive or limiting of this disclosure. Individual elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable and may be used in selected embodiments where applicable, even if not specifically shown or described. The same parts may also be varied in various ways. Such variations are not considered a departure from this disclosure, and all such modifications are intended to be included within the scope of the invention.

Claims

1. A self-aligning mechanical mounting and electrical connection system for an electronic module, the system comprising: Mechanical mounting components: The mechanical mounting assembly is configured to be integrated into or attached to the base frame, and The mechanical mounting assembly defines a mounting connection position guaranteeing CPA feature for self-aligning and securing the electronic module therein, wherein the electronic module defines a set of one or more robot mounting features configured to interact with the end effector of a robot mounter to lower the electronic module into the mechanical mounting assembly until the electronic module is secured in the mechanical mounting assembly by the mounting connection position guaranteeing CPA feature. as well as Electrical connection components: The electrical connection assembly is configured to be integrated into or attached to the mechanical mounting assembly, and The electrical connection assembly includes a modular electrical connector electrically connected to an electrical backbone cable and defined as a connector CPA feature for self-aligning the modular electrical connector with a corresponding electrical connector integrated into or attached to the electronic module when the electronic module is secured in the mechanical mounting assembly.

2. The system as described in claim 1, characterized in that, The base frame is the underframe or floor frame of an electrified vehicle, and the electronic module is configured to be vertically mounted by lowering the electronic module into the mechanical mounting assembly until the electronic module is secured in the mechanical mounting assembly by the mounting connection position.

3. The system as described in claim 2, characterized in that, The electrical backbone cable includes at least power cables and data cables, and wherein the electrical backbone cable is a basic flat cable extending along the underframe or floor frame of the electrified vehicle.

4. The system as described in claim 3, characterized in that, The system includes multiple electrical backbones, and at least a portion of said multiple electrical backbones are directly connected to each other via a bypass system, such that power or data circuits not required by the electronic module are bypassed by the electronic module.

5. The system as described in claim 3, characterized in that, Each modular electrical connector is positioned in an upward direction so that the corresponding electrical connector integrated into or attached to the electronic module can be installed perpendicular to the electronic module.

6. The system as described in claim 2, characterized in that, The mechanical mounting assembly is formed of sheet metal and integrated into the sheet metal portion of the underframe or floor frame of the electrified vehicle.

7. The system of claim 6, further comprising a set of heat transfer devices configured to transfer thermal energy from the electronic module.

8. The system as described in claim 7, characterized in that, The heat transfer device is a group of one or more heat transfer pads that transfer heat energy from the electronic module to the sheet-like metal portion of the underframe or floor frame of the electrified vehicle.

9. The system as described in claim 1, characterized in that, The electronic module is removable or configured to be released from the mechanical mounting assembly using special physical tools controlled by human technicians or robotic installers.

10. A method for mechanically mounting, aligning, and electrically connecting an electronic module, the method comprising: Mechanical mounting components are available. The mechanical mounting assembly is configured to be integrated into or attached to the base frame, and The mechanical mounting assembly defines a mounting connection position for self-aligning and securing the electronic module therein to ensure CPA features, wherein the electronic module defines a set of one or more robot mounting features; The end effector of the robot mounter interacts with the group of one or more robot mounting features, and the robot mounter lowers the electronic module into the mechanical mounting assembly until the electronic module is secured in the mechanical mounting assembly by the mounting connection position; and Provide electrical connection components: The electrical connection assembly is configured to be integrated into or attached to the mechanical mounting assembly, and The electrical connection assembly includes a modular electrical connector electrically connected to an electrical backbone cable and defined as a connector CPA feature for self-aligning the modular electrical connector with a corresponding electrical connector integrated into or attached to the electronic module when the electronic module is secured in the mechanical mounting assembly.

11. The method as described in claim 10, characterized in that, The base frame is the underframe or floor frame of an electrified vehicle, and further includes vertically mounting the electronic module by lowering it into the mechanical mounting assembly until the electronic module is secured in the mechanical mounting assembly by the mounting connection position, ensuring that the CPA feature is fixed in the mechanical mounting assembly.

12. The method as described in claim 11, characterized in that, The electrical backbone cable includes at least power cables and data cables, and wherein the electrical backbone cable is a basic flat cable extending along the underframe or floor frame of the electrified vehicle.

13. The method as described in claim 12, characterized in that, The electrical connection assembly includes a plurality of electrical backbone cables, and at least a portion of the plurality of electrical backbone cables are directly connected to each other via a bypass system, such that power circuits or data circuits not required by the electronic module are bypassed by the electronic module.

14. The method as described in claim 12, characterized in that, Each modular electrical connector is positioned in an upward direction so that the corresponding electrical connector integrated into or attached to the electronic module can be installed perpendicular to the electronic module.

15. The method as described in claim 11, characterized in that, The mechanical mounting assembly is formed of sheet metal and integrated into the sheet metal portion of the underframe or floor frame of the electrified vehicle.

16. The method of claim 15, further comprising providing a set of heat transfer devices configured to transfer thermal energy from the electronic module, wherein the set of heat transfer devices is a set of one or more heat transfer pads for transferring thermal energy from the electronic module to sheet-like metal portions of the underframe or floor frame of the electrified vehicle.

17. The method of claim 10, further comprising releasing the electronic module from the mechanically mounted assembly using specialized physical tools by a human technician or robotic installer, such that the electronic module can be removed.

18. A self-aligning mechanical mounting and electrical connection system for an electrified vehicle, the system comprising: An electronic module defining a set of one or more mounting features configured to lower the electronic module into a mechanical mounting assembly by interacting with an end effector of a robotic mounter or a human mounter until the electronic module is secured in the mechanical mounting assembly by a mounting connection position. The mechanical mounting assembly is configured to be integrated into or attached to the chassis of the electrified vehicle, and The mechanical mounting assembly is defined as a mounting connection position for self-aligning and securing the electronic module therein, ensuring CPA characteristics; as well as An electrical connection assembly configured to be integrated into or attached to the mechanical mounting assembly, and including an electrical connector for connection to the electronic module.

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