Plug-in force testing device

Abstract

This invention relates to a mating force testing apparatus. A testing apparatus for verifying the mating force of an electrical component having a slot for receiving one or more corresponding plugs in a push-fit arrangement. The testing apparatus includes a load plate having a supporting surface and orthogonally arranged first and second axes. A retainer holds the first electrical component on the load plate. A plurality of load units support the load plate at spaced-apart locations around the load plate. A mating force applied to the first electrical component via a second electrical component is transmitted to the plurality of load units. A processor is provided for receiving load unit data from the load units corresponding to the forces applied to each load unit. The processor determines the magnitude of the mating force and the position where the mating force is applied to the first electrical component relative to the first and second axes of the load plate based on the load unit data and the position of the load units relative to the load plate.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a test device for verifying a plug-in force during assembly of an automotive component, in particular to a device for verifying the magnitude of a plug-in force and the position of the plug-in force relative to an electrical connection point. BACKGROUND

[0002] Electrical components such as couplings, connectors, terminals and fuses are tested during assembly to ensure that they are inserted correctly. Process control systems can involve testing the insertion force during assembly to establish correct insertion. Withdrawal force can also be tested during the pull-out or disassembly process. The application of a consistent insertion force is necessary to ensure the safety of the electrical connection and to avoid accidental release of the connector in use.

[0003] Known methods for testing insertion force use an insertion tool with an electrical microswitch having a spring that holds the contact gap of the switch. The spring is selected so that compression below a given insertion force results in closure of the switch, which indicates that the required insertion force has been applied. Connection safety also depends on the point of application of the insertion force. If the force is applied off-center or away from the optimal point of application, it can be unbalanced and cause the connector to move out of correct alignment. As a result, the connector can be incorrectly and securely inserted despite the required insertion force being applied.

[0004] Automotive connectors experience significant vibration and acceleration forces during vehicle operation. Therefore, such connectors must be correctly seated and connected to prevent connection failure in use. The installation process for automotive electrical components such as fuse boxes can require the operator to apply the required verified insertion force, ensure that the component has been seated, and then pull the wires of the component to confirm safe seating. This test is known as a "push-seat-pull" test. After the push-seat-pull test is completed, a connector present assurance (CPA) test is performed to confirm that the electrical connection has been established and that electrical continuity exists.

[0005] Under certain conditions, the connector can not be fully and accurately inserted despite each of the required test steps being completed to the satisfaction of the operator. The insertion force and CPA test can indicate that the connector has been correctly inserted despite the connector being misaligned or not fully seated. As a result, the connector can become disconnected in use or in the vehicle during installation.

[0006] It is therefore desirable to provide an improved test device which addresses the above problems and / or provides an overall improvement. SUMMARY

[0007] According to the present disclosure, there is provided a test device for verifying a plug-in force as described herein.

[0008] In one aspect of the disclosure, a test device for verifying insertion force during assembly of a first electrical component having one or more electrical connection points for receiving one or more corresponding second electrical components in a push-in fit arrangement is provided. The test device includes a load board having a support surface and first and second axes arranged orthogonally, the first and second axes being defined parallel to the support surface. A holder is provided for holding the first electrical component on the load board. A plurality of load cells support the load board and are arranged at spaced apart locations about the load board such that an insertion force applied to the first electrical component held on the load board via the second electrical components in a direction normal to the support surface of the load board is transmitted to the plurality of load cells. A processor is provided for receiving load cell data corresponding to the force respectively applied to each load cell from the load cells. The processor is operable to determine a magnitude of the insertion force and a location of the insertion force relative to the first and second axes of the load board applied to the first electrical component based on the load cell data and the location of the load cells relative to the load board.

[0009] The first electrical component can be a fuse block and the second electrical components can be one or more fuses, which can include relays, connectors or other attachment components. The first and second axes are orthogonal x, y axes defined across the surface of the load board. The term "holder" refers to any component capable of holding the first electrical component in a fixed position on the load board during insertion of the second electrical components. The holder is also preferably capable of holding the first electrical component in place on the load board when a pull-out force is applied to the second electrical components. The processor preferably includes a computer running software performing the operations required of the processor. The term "load cell data" can include electrical signals, digital information or any other load cell output.

[0010] Preferably, the processor is programmed with location information relating to the location of one or more receptacles of the first electrical component on the load board when the first electrical component is held in the holder. The location information is the x, y coordinates of each receptacle and the location at which an insertion force must be applied to each fuse or other component when inserted into the receptacle. The processor is operable to compare the determined x, y location of the point of application of the insertion force to the expected location and provide an output based on the comparison. The output can be an indication as to whether the insertion force was applied at the correct x, y location. The required x, y location can have a tolerance radius within which the point of insertion force can be considered to be compliant.

[0011] The processor can be programmed with force information relating to a desired size of the insertion force for each socket, and operable to compare the determined size of the insertion force for each socket to the desired insertion force, and provide an output based on the comparison. The desired size is a minimum force threshold that must be met to provide an adequate assurance that the second component has been fully seated within the socket and can be defined by the component manufacturer. The processor can also determine whether a maximum force threshold is reached, above which there is a risk of damage to the first component and / or the second component, and can provide an alert if the maximum threshold is reached.

[0012] A visual display unit can be provided, and the processor can be operable to display a visual representation of the load board and the first electrical component on the visual display unit, and to generate and display a visual marker of the location of the insertion force. The visual representation can be a pre-generated image, such as a photograph or a graphical representation of the load board and the first electrical component stored on a computer readable memory of the processor, or can be a live image captured by a camera. The image can alternatively comprise an image of the first electrical component positioned on a 2D grid representing the x, y coordinates of the load board. The marker can be a graphical image superimposed on the visual representation to indicate the point of application of the insertion force. The processor can also be operable to generate and display a marker of the size of the insertion force. The force marker can be separate from the location marker, or can be defined by the first marker. For example, the first marker can vary in size or colour depending on the size of the force.

[0013] The load unit is preferably mounted to a support structure at a first proximal end and connected to the load board at a second distal end. The support structure can be a support frame, a base plate positioned beneath the load unit, or any other structure suitable to support the load unit while the load unit holds the load board in a suspended arrangement.

[0014] The load board can comprise a third load axis (z-axis) arranged perpendicular to the first and second axes, and the load unit is arranged to support the load board in the direction of the third load axis. Preferably, the load board is arranged horizontally, with the x, y axes being horizontal axes and the z-axis being a vertical axis.

[0015] The load unit can comprise a plurality of strain gauges mounted on its opposing upper and lower surfaces. The load unit can be operable to determine the direction and size of the force applied to the load board along the third load axis based on the output of the strain gauges.

[0016] The processor can be operable to determine whether the force applied to the load board is an insertion force directed towards the support surface of the load board or a pull-out force directed away from the support surface of the load board based on whether the load unit signal is positive or negative, the insertion force and the pull-out force being in the third load axis.

[0017] The processor is operable to verify the test procedure, which comprises a first step of inserting the second electrical component into the socket of the first electrical component and applying a plug-in force to the second electrical component and a second step of unplugging the second electrical component to ensure that the second electrical component is correctly seated in the socket. The processor is operable to verify the first step by determining the magnitude and location of the plug-in force and comparing the magnitude and location of the plug-in force to a required plug-in force magnitude threshold and location relative to the first and second axes respectively, and wherein the processor is operable to confirm that the first step has been correctly performed if it is determined that the plug-in force has been applied at the correct location and the plug-in force threshold has been met. The processor determines the x,y coordinates of the location at which the plug-in force is applied and compares this x,y location to the x,y coordinates of the required application point to determine whether the plug-in force has been applied at the correct location.

[0018] The processor is operable to verify the second step by determining the magnitude of the unplug force and comparing it to a required unplug force threshold. The processor is operable to confirm that the second step has been correctly performed if it is determined that the unplug force has been applied at the correct location and the unplug force threshold has been met. The processor can also determine the location at which the unplug force is applied which can be used to confirm that for example the correct fuse has been unplugged.

[0019] The load plate can comprise a peripheral edge and the load cells are arranged around the periphery of the load plate. The load cells are preferably located below the load plate with the load plate mounted on the load cells. The load plate can comprise a plate and a support frame on which the plate is mounted. The load cells are preferably connected to the support frame of the load plate.

[0020] Each load cell is preferably mounted at a first end to a support element, which can be a rigid structure, and extends in a cantilevered arrangement from the support element. An opposite second end is connected to the load plate. Preferably, the load cells and support elements are located below the load plate and within the perimeter or footprint of the load cells.

[0021] In another aspect of the application there is provided a method of performing a plug-in force verification test, the method comprising the steps of:

[0022] providing a test apparatus according to described herein;

[0023] inserting and retaining a first electrical component in the retainer;

[0024] inserting a second electrical component into a socket of the first electrical component and applying a plug-in force to the second electrical component;

[0025] The testing apparatus is used to verify whether the insertion force meets the insertion force threshold and whether the insertion force is applied at a predetermined desired position relative to the first axis and the second axis of the load plate.

[0026] The method may further include the following steps: after inserting the second electrical component, applying a pull-out force to the second electrical component and verifying whether the pull-out force meets the pull-out force threshold and whether it is applied at the desired position relative to the first axis and the second axis.

[0027] The method may also include displaying images of electrical components on the display unit and indicating the location and / or magnitude of insertion and / or extraction forces on the display unit.

[0028] The method may also include providing feedback signals to the operator to confirm whether the insertion force threshold has been reached.

[0029] The method may also include providing an indication that the mating force verification test has been successfully completed if it is determined that the mating force threshold has been reached and the mating force has been applied at the correct location. Attached Figure Description

[0030] This disclosure will now be described by way of example only with reference to the following illustrative drawings, in which:

[0031] Figure 1 These are illustrative views of a testing apparatus according to embodiments of the present disclosure;

[0032] Figure 2 This is a side view of a test apparatus according to an embodiment of the present disclosure, showing the damper arrangement of the load unit;

[0033] Figure 3 This is a circuit diagram of a load unit according to an embodiment of the present disclosure;

[0034] Figure 4 This is a circuit diagram of a series of load units according to embodiments of the present disclosure;

[0035] Figure 5 These are illustrative views of a testing apparatus according to embodiments of the present disclosure; and

[0036] Figure 6 yes Figure 5 A view of the internal structure of the test apparatus. Detailed Implementation

[0037] The following description presents exemplary embodiments, and is consistent with the appendix. Figure 1This disclosure is intended to explain the principles of the present disclosure. The scope of this disclosure is not intended to be limited to the precise details of the embodiments or to exact adherence to all method steps. Variations will be apparent to those skilled in the art and are considered to be covered by the specification. The terminology used herein should be given a broad interpretation that also covers equivalent functions and features. In some cases, several alternative terms (synonyms) have been provided for structural features, but these terms are not intended to be exhaustive.

[0038] Descriptive terms should also be given the broadest possible interpretation; for example, the term "comprising" as used in this specification means "consisting of at least partially," such that each statement using the term "comprising" in this specification is interpreted as allowing the presence of features other than that term or features cited by that term. Related terms such as "comprising" and "including" will be interpreted in the same manner. Directional terms such as "vertical," "horizontal," "upward," "downward," "above," and "below" are relative terms generally used with reference to the accompanying drawings for ease of interpretation and are not intended to ultimately limit whether equivalent functionality can be achieved with alternative dimensions and / or directions.

[0039] The description herein relates to implementations having specific combinations of configuration steps or features. However, it is conceivable that further combinations and cross-combinations of compatible steps or features between implementations will be possible. The description of multiple features of any particular implementation is not an indication that such features are inseparably linked, and isolated features may function independently of other features and are not necessarily required to be implemented as a complete combination.

[0040] Reference Figure 1 A system for testing the insertion of electrical automotive components includes a horizontally arranged load plate 2 mounted on an inner frame 4. The load plate 2 includes a retainer 5 on its upper surface for receiving and holding a fuse box 7 having multiple electrical connection points 9 in the form of slots to which multiple corresponding fuses will be connected. However, it should be understood that this disclosure can be applied to any electrical component or device configured to receive one or more corresponding electrical connectors. The inner frame 4 includes four frame members 6 arranged in a square or rectangular configuration. These frame members include a pair of first frame members 8a and second frame members 8b arranged parallel to each other, and a pair of third frame members 10a and fourth frame members 10b arranged parallel to each other. The first frame members 8a and second frame members 8b are connected to and orthogonal to the third frame members 10a and fourth frame members 10b.

[0041] The inner frame 4 is mounted to and suspended within the outer frame 11. The inner frame 4 is mounted to the outer frame 11 via a plurality of load units 12 spaced apart around the inner frame 4. A first load unit 12 and a second load unit 14 are connected to a first frame member 8a. The first load unit 12 and the second load unit 14 are spaced apart from each other along the first frame member 8a and are located at opposite ends of the first frame member 8a near the third frame member 10a and the fourth frame member 10b, respectively. The first load unit 12 and the second load unit 14 have an upper surface 13 and a lower surface 15. The first frame member 8a is mounted to each of the first load unit 12 and the second load unit 14 at spaced-apart positions above the upper surface 13 of each load unit 12, 14.

[0042] A guide pin 16 connects the first frame member 8a to each load unit 12, 14. The guide pin 16 is rigidly fixed to the inner end of the load units 12, 14 and extends through the upper surface 13 and lower surface 15. A first spring 20 is positioned about the guide pin 16 between the upper surface 13 of the load units 12, 14 and the lower surface of the first frame member 8a. The guide pin extends through the first frame member 8a and has an enlarged diameter head 22 at its upper end. A second spring 25 is positioned about the guide pin 16 between the upper surface of the first frame member 8a and the head 22. The first frame member 8a is slidably supported on the guide pin 16 and is movable upward and downward away from and towards the load units 12, 14. When the first frame member 8a is pushed downward or upward, the first spring 20 and the second spring 25 act as dampers. Damping the connection between the load unit and the inner frame, rather than providing a rigid connection, ensures that the load units do not require recalibration after installation. The damped connection also reduces tension in the frame and ensures effective force distribution between the load units.

[0043] The third load unit 16 and the fourth load unit 18 are connected to the second frame member 8b. The third load unit 16 and the fourth load unit 18 are spaced apart from each other along the second frame member 8b and are located at opposite ends of the second frame member 8b near the third frame member 10a and the fourth frame member 10b, respectively. Load units 16, 18 have an upper surface 17 and a lower surface 19. The second frame member 8b is mounted to each of the third load unit 16 and the fourth load unit 18 at a spaced-apart position above the upper surface 13 of each load unit 12, 14. Similar to the first frame member 8a, a guide pin 16 connects the second frame member 8b to each load unit 16, 18. The guide pin 16 is rigidly fixed to the inner end of the load units 16, 18. A first spring 20 is positioned around the guide pin 16 between the upper surface 17 of the load units 16, 18 and the lower surface of the second frame member 8b. A second spring 25 is positioned around the guide pin 16 between the upper surface 17 of the second frame member 8b and the head 22. The second frame member 8b is slidably supported on the guide pin 16 and is able to move upward and downward away from and toward the load units 16, 18.

[0044] Load units 12, 14, 16, and 18 are tensometric beams, connected at their inner ends to the inner frame 4 and at their outer ends to the outer frame 11. The outer ends of the load units are cantilevered to the outer frame, and the outer end of each load unit 12, 14, 16, and 18 is mounted on the upper surface of the outer frame 11 and protrudes inward from the outer frame 11 toward the inner frame 4. The distance between the connection point of each load unit 12, 14, 16, and 18 to the outer frame 11 and the connection point of each load unit 12, 14, 16, and 18 to the inner frame 4 defines the lever arm.

[0045] A retainer 5 is arranged to receive and hold the fuse box 7, such that the fuse box 7 is rigidly fixed within the retainer 5 and relative to the inner frame 4. In this manner, the force applied to the fuse box 7 is transmitted to the inner frame 4 via a load plate 2. The load plate has a first horizontal x-axis and a second horizontal y-axis orthogonal to the x-axis. A first frame member 8a and a second frame member 8b are arranged along the x-axis, and a third frame member 10a and a fourth frame member 10b are arranged along the y-axis. A vertical z-axis is orthogonal to the x and y axes. The vertical / vertical force applied to the fuse box 7 along the z-axis is transmitted to and distributed among the load units 12, 14, 16, and 18. The load units 12, 14, 16, and 18 are configured and operated to measure the value of the force vector applied to the load unit along the z-axis. The load units 12, 14, 16, and 18 are configured to measure the z-axis force vector in both the positive direction corresponding to a downward "push" force and the negative direction corresponding to an upward "pull" force.

[0046] likeFigure 2 As shown, the operating principle of the load units 12, 14, 16, and 18 used to measure the force applied to the load plate 2 relies on strain gauges disposed on the outer surfaces of the load units 12, 14, 16, and 18. The strain gauges can, for example, comprise bonded / adhesive metal strain gauges composed of a mesh of very fine wires or metal foil. A first pair of strain gauges 24 and 26 are installed at intervals along the length of the upper surface of each load unit 12, 14, 16, and 18. A second pair of strain gauges 28 and 30 are installed at intervals along the length of the lower surface of each load unit 12, 14, 16, and 18.

[0047] The strain gauges in each load unit 12, 14, 16, and 18 are respectively configured as follows: Figure 3 The Wheatstone bridge connection is shown. The output voltage Vo is measured as the difference between the output voltage '+' and the output voltage '-', and varies depending on the load cell to which the load is applied. Figure 4 As shown, each load cell 12, 14, 16, 18 is connected to dedicated PCBs 30, 32, 34, 36, which are configured to function as load cell amplifiers. The output voltage signal Vo from each load cell 12, 14, 16, 18 is amplified by the dedicated load cell amplifiers 30, 32, 34, 36, which convert the measured analog output Vo into a digital signal. The digital output signal from each load cell amplifier 30, 32, 34, 36 is transmitted to a microcontroller 40. The microcontroller converts the signal from each load cell amplifier 30, 32, 34, 36 into a value indicating the load applied to each corresponding load cell 12, 14, 16, 18.

[0048] The force applied to the component received by the retainer 5 is transmitted to the load plate 2. The applied force is then distributed among the individual load units 12, 14, 16, 18. The x and y positions of the forces applied on the load plate can be determined based on the force distribution on each load unit 12, 14, 16, 18. The forces are applied to the load plate 2 at the x and y positions. The x and y axes are arranged relative to the load plate 2 and the load units 12, 14, 16, 18 such that the first load unit 12 and the fourth load unit 18 (A, D), and the second load unit 14 and the third load unit 16 (B, C) are respectively arranged at a common y position. The third load unit 16 and the fourth load unit 18 (C, D), and the first load unit 12 and the second load unit 14 (A, B) are respectively arranged at a common x position. The first load unit 12 and the fourth load unit 18 (A, D) are arranged at the x position. o The third load unit 16 and the fourth load unit 18 (C, D) are arranged at y o Place.

[0049] During the application of the applied force, the inner frame 4 remains stationary. Therefore, the sum of the torques applied across load cells 12, 14, 16, and 18 is zero. The value of the force vector is the sum of the readings for all four load cells 12, 14, 16, and 18:

[0050] Sum_12_14_16_18=scale_12_read+scale_14_read+scale_16_read+scale_18_read

[0051] By calculating which part of the total force vector is at a distance x... o y o The x and y coordinates of the applied force are determined by measurements taken from the load element at the common x and y positions of the axis. Therefore, x and y are the coordinates calculated as follows:

[0052] X=(scale_12_read+scale_14_read) / Sum_12_14_16_18

[0053] Y=(scale_16_read+scale_18_read) / Sum_12_14_16_18

[0054] Load cells 12, 14, 16, and 18 are arranged such that if the applied force is positive (i.e., downward), the output of each load cell 12, 14, 16, and 18 is positive, and if the force is applied in the opposite upward direction, the output of each load cell 12, 14, 16, and 18 is negative. Therefore, load cells 12, 14, 16, and 18 can be used to determine the magnitude, location, and direction of the applied force during the 'push' and 'pull' tests.

[0055] Microcontroller 40 may be an ESP 8266 microcontroller and is configured to sample data from load unit amplifiers 30, 32, 34, and 36 at a high frequency, and process the load unit amplifier data to calculate the x, y coordinates and magnitude of the applied force. The microprocessor data is provided to a PC, which provides a user interface for performing a 'push-and-pull' test. The PC is programmed with information relating to the shape and size of the fuse box or other components, the location of the slots to which the connectors are to be supplied, and the desired location of the force applied to each connector. The PC is also programmed with the x, y positions of the retainer 5 and the fuse box on the load board 2, as well as the x, y positions of each slot.

[0056] Before inserting the component, the load cells are automatically tare to zero the reading of each load cell, taking into account the weight of load plate 2 and the fuse box. The automatic tare function is operated by a microcontroller. The microcontroller's automatic tare function includes detecting a stable reading from each load cell, indicating that the insertion or extraction force has stopped, and detecting the automatic tare stable reading. The automatic tare process is completed after each push-lock-pull test.

[0057] When the fuse is inserted, the x and y positions of the applied force are calculated. The position and magnitude of the applied force are cross-referenced to the required force position and magnitude for the corresponding fuse. It is determined whether the applied force is of sufficient magnitude and applied in the correct position. Manual and audible feedback is also used to determine if the fuse is properly engaged. The user then applies a pull-out force to the fuse. This pull-out force is also detected and cross-referenced to determine if it is of sufficient magnitude and applied in the correct position. If it is determined that the insertion (push) force and retraction (pull-out) force were applied, and that the correct position and sufficient magnitude were achieved, a positive signal is generated indicating that the test was performed correctly.

[0058] Additionally, the PC can provide a graphical representation of the load board and fuse box, which can be a pre-loaded image of the load board 2 or a real-time captured image from a camera. The image of the load board is overlaid with an x, y grid and features of the image (including the perimeter of the fuse box), and the slots are assigned x, y coordinates. A display image is generated that includes the fuse box on the load board 2, on which the position of the applied force is represented based on the calculated x, y positions. This real-time visualization of the measured force vector relative to the fuse box provides immediate feedback to the operator. The system can be configured to provide audio and / or visual feedback for successful or unsuccessful test completion. The software can be configured to allow the operator to change parameters such as the force threshold and other settings.

[0059] Visual displays can provide guidance to the operator during testing, for example, indicating the desired location of the applied force and / or the direction of the force required for a given test step, and verifying the correct application of the force at each step.

[0060] The PC can be programmed with configuration data for a range of electrical components and a series of corresponding test procedures and protocols. Therefore, the system can be applied to verify the mating force of any component.

[0061] In alternative implementations, such as Figure 5As shown, a load plate 102 is mounted on a load plate frame 104. A retainer 105 is located on the upper surface of the load plate 102. The retainer 105 has a recess shaped to receive a fuse box 107, which has a plurality of slots 9 to which a plurality of corresponding fuses will be connected. The load plate frame 104 includes a pair of first frame members 108a and second frame members 108b arranged parallel to each other, and a pair of third frame members 110a and fourth frame members 110b arranged parallel to each other. The first frame members 108a and second frame members 108b are connected to the third frame members 110a and fourth frame members 110b.

[0062] Load units 112, 114, 116, and 118 are mounted to substrate 140. Substrate 140 is located below load plate 102 and load plate frame 104. However, it should be understood that in other embodiments, the load plate may be directly supported on the load units and the load plate frame may not be required, wherein the load units are directly connected to the lower surface of the load plate instead of the load plate frame. Figure 6 A substrate 140 and load units 112, 114, 116, and 118 are shown, with the load plate 102 indicated by dashed lines. Load units 112, 114, 116, and 118 are each mounted to the substrate 140 via rigid support blocks 144, which space the first ends of the load units 112, 114, 116, and 118 from the substrate 140. The load units 112, 114, 116, and 118 extend horizontally from their respective support blocks 144 in a cantilevered arrangement. The first load unit 112 and the second load unit 114 are longitudinally aligned with the edges of the first frame member 108a and the load plate 102. The first load unit 112 is spaced below the first frame member 108a and connected to the first end of the first frame member 108a via a first pair of rubber dampers 148. The support blocks 144 are located inside the first end along the length of the first frame member 108a. The second load unit 114 is similarly spaced below the first frame member 108a and connected to the second end of the first frame member 108a via a second pair of rubber dampers 150. The support block 144 of the second load unit 114 is located inside the second end along the length of the first frame member 108a. The first damper 148 and the second damper 150 provide a damped connection between the first frame member 108a and the load units 112, 114.

[0063] The third load unit 116 and the fourth load unit 118 are connected to the base plate 140 and the second frame member 108b in a similar manner. The third load unit 114 and the fourth load unit 116 are longitudinally aligned with the second frame member 108b, which is located on the side of the inner frame 4 opposite to the first frame member 108a. The third load unit 116 is spaced below the second frame member 108b and connected to the first end of the second frame member 108b via a third pair of rubber damper members 152. The damper members 152 of the third load unit 116 are located inside the first end along the length of the second frame member 108b. The fourth load unit 118 is connected to the second end of the second frame member 108b via a fourth pair of rubber damper members 154. The damper members 154 of the fourth load unit 118 are located inside the second end along the length of the second frame member 108b. In this embodiment, the load plate frame 104 is therefore supported by load units 112, 114, 116, and 118 in a cantilever arrangement. The load units 112, 114, 116, and 118 are mounted to the substrate 140 within the space occupied by the load plate frame 104 and extend outward toward the outer edge of the load plate frame 104, rather than being mounted to an external frame and extending inward toward the load plate frame 104 as in the first embodiment, thereby achieving a more compact arrangement.

Claims

1. A testing apparatus for verifying the insertion force during assembly of a first electrical component, the first electrical component having one or more electrical connection points for receiving one or more corresponding second electrical components in a push-fit arrangement, the testing apparatus comprising: A load plate having a support surface and orthogonally arranged first and second axes, the first and second axes being defined as parallel to the support surface; A retainer for holding the first electrical component on the load plate; Multiple load units support the load plate and are arranged at spaced positions around the load plate, such that an insertion force applied to the first electrical component held on the load plate in a direction perpendicular to the support surface of the load plate is transmitted to the multiple load units. A processor is configured to receive load unit data from the load units corresponding to the forces applied to each load unit respectively; The processor is operable to determine the magnitude of the insertion force and the position of the insertion force relative to the first axis and the second axis of the load plate applied to the first electrical component based on the load unit data and the position of the load unit relative to the load plate.

2. The testing apparatus according to claim 1, wherein, The processor is programmed with positional information relating to the position of one or more electrical connection points of the first electrical component on the load plate when the first electrical component is held in the retainer, and a desired position of the insertion force for each electrical connection point, and the processor is operable to compare the determined application point of the insertion force with the desired position, and provide an output based on the comparison.

3. The testing apparatus according to claim 1 or 2, wherein, The processor is programmed with force information relating to the expected magnitude of the insertion force for each electrical connection point, and is operable to compare the determined magnitude of the insertion force for each electrical connection point with the expected insertion force and provide an output based on the comparison.

4. The testing apparatus according to claim 1, further comprising a visual display unit, wherein, The processor is operable to display a visual representation of the load plate and the first electrical component on the visual display unit, and to generate and display visual markings of the position of the insertion force.

5. The testing apparatus according to claim 1, wherein, The load unit is mounted to the support structure at the first proximal end and connected to the load plate at the second distal end.

6. The testing apparatus according to claim 1, wherein, The load plate includes a third load axis arranged perpendicular to the first axis and the second axis, and the load unit is arranged to support the load plate in the direction of the third load axis.

7. The testing apparatus according to claim 6, wherein, The load unit is operable to determine the direction and magnitude of the force applied to the load plate along the third load axis.

8. The testing apparatus according to claim 7, wherein, The processor is operable to determine, based on the load cell data, whether the force applied to the load plate is an insertion force pointing toward the support surface of the load plate or a pull-out force pointing away from the support surface of the load plate along the third load axis.

9. The testing apparatus according to claim 8, wherein, The processor is operable to verify the completion of a test process, the test process including a first step of inserting a second electrical component into a slot of a first electrical component and applying a mating force to the second electrical component, and a second step of removing the second electrical component to ensure that the second electrical component is correctly positioned in the slot. The processor is operable to verify the completion of the first step by determining the magnitude and position of the mating force and comparing the magnitude and position of the mating force with a required mating force magnitude threshold and a position relative to the first axis and the second axis, respectively. The processor is operable to confirm that the first step has been performed correctly if it is determined that the mating force has been applied at the correct position and the mating force magnitude threshold has been met.

10. The testing apparatus according to claim 9, wherein, The processor is operable to verify the second step by determining the magnitude of the pull-out force and comparing it with a required pull-out force threshold, wherein the processor is operable to confirm that the second step has been performed correctly if it is determined that the pull-out force has met the pull-out force threshold.

11. The testing apparatus according to claim 9 or 10, wherein, The processor is operable to determine the location of the pull-out force and compare the determined location with the desired location to confirm that the pull-out force is applied to the correct second electrical component.

12. The testing apparatus according to any one of claims 6 to 10, wherein, The load plate includes a peripheral edge, and the load units are arranged around the periphery of the load plate, and / or, a damper member is positioned between each load unit and the load plate.

13. The testing apparatus according to any one of claims 1 to 2, 4 to 10, wherein, The one or more electrical connection points include electrical slots, and the one or more corresponding second electrical components include plug elements configured to be received by one or more corresponding slots.

14. A method for performing a mating force verification test, the method comprising the following steps: Provide a testing apparatus according to any one of claims 1 to 13; Insert the first electrical component into the retainer; Insert the second electrical component into the slot of the first electrical component and apply insertion force to the second electrical component; Verify whether the insertion force meets the insertion force threshold; as well as Verify that the insertion force is applied at the desired position relative to the first axis and the second axis.

15. The method for performing a mating force verification test according to claim 14, the method further comprising the following steps: After the second electrical component is inserted, a pull-out force is applied to the second electrical component; as well as Verify whether the pull-out force meets the pull-out force threshold.

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