Intelligent connector assembly

Abstract

A connector assembly is disclosed that includes a base having an embedded printed circuit board (PCB) and a plurality of signal pins. The plurality of signal pins electrically couple the PCB to a vehicle wire harness. The connector assembly includes a mating connector for mechanically coupling the connection assembly to the vehicle harness and a spring between the mating connector and the base. The spring preloads and axially secures the base to the mating connector. The connector assembly transmits vehicle signals through a wireless connection with a vehicle and / or a remote location.

Description

Technical Field

[0001] The present invention relates generally to vehicle controls and, more particularly, to an integrated removable connector and associated mounting hardware for removably connecting an electrical circuit to a vehicle control system. Background Art

[0002] Vehicle systems generate electrical signals that are transmitted to and / or from the ECU and / or other controllers via the vehicle wiring harness. These signals can provide vehicle performance information and alert the vehicle operator and / or maintenance personnel to vehicle system health. However, many times this information is not considered until an incident occurs, for example, low oil levels can cause poor vehicle performance and, in some cases, prime mover failure. Existing systems and devices have various shortcomings in providing real-time monitoring of vehicle signals by the vehicle operator and / or a remote location. Summary of the invention

[0003] An integrated connector assembly is disclosed herein. In one embodiment, the connector assembly for integration with a vehicle signal harness is disclosed. The connector assembly can provide distributed processing capabilities with wireless connectivity. The connector assembly includes a base having an embedded printed circuit board (PCB) and a plurality of signal pins. The plurality of signal pins electrically couple the PCB to the vehicle harness. The connector assembly may include a mating connector for mechanically coupling the connector assembly to the vehicle harness, and a spring between the mating connector and the base. The spring preloads and axially secures the base to the mating connector, and the spring may be, for example, a wave spring washer.

[0004] The mating connector may be configured to lock with the vehicle wiring harness, for example, may be connected to an oil level sensor signal. The connector assembly may include an insulator positioned between the base and the mating connector. The insulator may be configured to receive the plurality of signal pins therefrom. The connector assembly may include a wireless connection between the connector assembly and a plurality of receivers. The wireless connection may include at least one of a Bluetooth and a telematics connection.

[0005] The base of the connector assembly may define a plurality of axially extending channels to receive the plurality of signal pins. The base may include a circumferential groove, and the mating connector may include an inner radial groove aligned with the circumferential groove to receive the spring therebetween. The base may include a first body portion that houses the PCB; a second body portion that extends axially from the first body portion; and a third body portion that extends axially from the second body portion. The mating connector may be positioned around the second body portion and the third body portion.

[0006] The third body portion may have a reduced diameter compared to the second body portion, and the third body portion may include a plurality of axially extending ribs extending along an outer surface of the third body portion. The third body portion may include a radially extending flange protruding outwardly from the outer surface of the third body portion, and the flange and the second body portion may define a circumferential groove therebetween for receiving the spring. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The description herein refers to the accompanying drawings, wherein like reference numerals refer to like parts throughout the several views, and wherein:

[0008] Figure 1 is a block diagram of an embodiment of a hardware configuration of the present disclosure;

[0009] Figure 2 is an exploded view of an embodiment of a connector assembly of the present disclosure;

[0010] Figure 3 yes Figure 2 Other exploded views of connector assemblies;

[0011] Figure 4A is with Figure 2 A top view of an embodiment of a base for use with a connector assembly;

[0012] Figure 4B yes Figure 4A A cross-sectional view of a base;

[0013] Figure 5A is with Figure 2 A top view of an embodiment of an insulator for use with a connector assembly;

[0014] Figure 5B yes Figure 5A A partial cross-sectional view of an insulator;

[0015] Fig. 6A is with Figure 2 a top view of a mating connector for use with the connector assembly; and

[0016] Figure 6B yes Fig. 6A A cross-sectional view of an embodiment of a mating connector. DETAILED DESCRIPTION

[0017] For the purpose of promoting an understanding of the principles of the invention, reference will now be made to the embodiments shown in the drawings and specific language will be used to describe the same. It will be understood, however, that the scope of the invention is not thereby limited and that such changes and further modifications in the illustrated apparatus and such further applications of the principles of the invention as herein illustrated would normally occur to one skilled in the art to which the invention relates.

[0018] Figure 1 1 is a diagram of an embodiment of a smart connector (SC) system 100. The system 100 includes a connector assembly 102, a vehicle wiring harness 105, and an electrical connector 104. A wireless connection 110 transmits signals from the connector assembly 102 to various remote users or systems, such as a vehicle. The remote systems or users of the vehicle may include, for example, a vehicle engine control unit (ECU) 120, one or more output devices 122 in or on the vehicle, a service department 124 that services the vehicle, an owner or customer 126, and various other remote locations and devices. The connector system 100 may be connected to sensors or devices, such as a vehicle, to collect, store, and wirelessly transmit data to remote systems and / or users using Bluetooth, WiFi, cellular, and / or any other suitable wireless or telematics protocol or connection.

[0019] Figure 2 is a diagram of an embodiment of a connector assembly 102, which includes Figure 2 2, and the like. The base 210, wave spring 250, and mating connector 270 are shown in exploded view in FIG. The base 210 can be coupled to the mating connector 270 using a preload locking mechanism, such as the wave spring 250 as discussed further below. The wave spring 250 can be located between the base 210 and the mating connector 270. The wave spring 250 can be used to provide a preload to securely hold the mating connector 270 on the base 210. In other embodiments, any suitable preload member or mechanism is contemplated.

[0020] Figure 32 is another exploded view of the connector assembly 102. The base 210 includes a first body portion 212 extending axially from an outer end to a first axially facing face 213, a second body portion 214 extending axially from the first face 213, a second axially facing surface 215, a third body portion 217 extending axially from the second face 215, a plurality of axially extending ribs 216 on the outer surface of the third body portion 217, and a top surface 218 at the outer end of the third body portion 217. In the illustrated embodiment, the body portions 212, 214, 217 are cylindrical, but other shapes are not excluded. Compared to the second body portion 214, the third body portion 217 has a reduced diameter. A printed circuit board (PCB) 230 having a plurality of surface mount components 232 is embedded in the base 210, and particularly in the first body portion 212 between the outer end of the first body portion 212 and the first face 213.

[0021] The third body portion 217 defines a plurality of holes 220 that open at a top surface 218 and extend to the PCB 230. The base 210 is overmolded around the PCB 230 and a separator or insulator 235 that accommodates pins 240 connected to the PCB 230. The insulator 235 is positioned relative to the base 210 at the top surface 218. The insulator 235 also has a plurality of holes 236 configured to receive a plurality of signal pins 240. Each of the plurality of signal pins 240 receives a signal from the vehicle harness 105 through the electrical connector 104. The PCB 230 includes a top surface 231 having a plurality of electrical contacts 233 that are electrically connected to the plurality of signal pins 240 when the insulator 235 having the plurality of signal pins 240 is fixed to the base 210 adjacent to the top surface 218 and the plurality of signal pins are inserted into the holes 220.

[0022] The wave spring 250 includes the shape of an open-side washer that is capable of being inserted into a circumferential groove 225 ( 226 ) between the second axially facing surface 215 of the base 210 and the radial flange 226 . Figure 4B ) is expanded and positioned around the third body portion 217 of the base 210. The body of the wave spring 250 is resilient, so that it rebounds to remain installed around the third body portion 217 within the circumferential groove 225. The mating connector 270 is first coupled to the base 210 around the top surface 218 and can be guided along the ribs 216 as the mating connector 270 advances along the third body portion 217. The mating connector 270 can advance along the third body portion 217 until the bottom 271 of the mating connector 270 is adjacent to the first axially facing surface 213 and contacts the wave spring 250 therebetween.

[0023] Figure 4A is a top view of the base 210, and Figure 4B 2 is a cross-sectional view of the base 210. The top surface 218 of the base 210 is located adjacent to the insulator 235 and the signal pins 240, and the pins 240 are received in the plurality of holes 220. When the connector assembly 102 is fully assembled, the second side 215 of the base 210 is the surface adjacent to the bottom 271 of the mating connector 270. The plurality of holes 220 are formed by molding the insulator 235 around the signal pins 240, and forming a plurality of channels 221 configured to accommodate the signal pins 240. The PCB 230 is embedded in the first body portion 212 of the base 210, located between its outer end opposite to the top surface 218 and the first axially facing surface 213. The plurality of signal pins 240 are located in the plurality of holes 220 and the plurality of channels 221 on the top surface 218, and contact the plurality of electrical contacts 233 on the top surface 231 of the PCB 230. When the connector assembly 102 is fully assembled and the mating connector 270 is placed in a locked position on the base 210, the groove 225 formed between the flange 226 and the second axially facing surface 215 and extending around the third body portion 217 can be used to lock and axially secure the base 210 and the mating connector 270 together.

[0024] Figure 5A An insulator 235 is shown including holes 236 that align with the holes 220 on the top surface 218 of the base 210 . Figure 5B 2 is a cross-sectional view of the insulator 235 showing a plurality of channels 237 defined by holes 236 for a plurality of signal pins 240. The insulator 235 may optionally include mounting legs 241 extending axially from its bottom surface to mounting leg ends 242 engaging the top surface 218 of the base 210 to secure the insulator 235 to the base 210.

[0025] Fig. 6A 2 is an illustration of a top view of a mating connector 270 including a plurality of locating keyways 272 that align adjacent to a plurality of locating keys (not shown) on the vehicle harness 105 when the mating connector 270 engages the vehicle harness 105. A plurality of gripping serrations 274 may be positioned around the periphery of the mating connector 270 to assist in mating the connector 270 to the base 210 and / or for twisting the connector assembly to engage with the vehicle harness 105.

[0026] Figure 6B2 is a cross-sectional view of the mating connector 270, showing the locking rotation groove 276. The locking rotation groove 276 is fixed to a mating protrusion (not shown) on the vehicle wiring harness 105 to mechanically couple the connector assembly 102 to the vehicle wiring harness 105. The mating connection 270 also includes a tapered inner wall 279, which helps position and compress the wave spring 250 as the inner wall slides along the wave spring 250 until the wave spring 250 passes through the lip 281 and snaps into the inner circumferential groove 278. When the mating connector 270 is engaged with the third body portion 217 of the base 210, the wave spring 250 is received in the inner circumferential groove 278 of the mating connector 270 and in the axially aligned circumferential groove 225 of the base 210. The wave spring 250 thus axially fixes the base 210 with the mating connector 217.

[0027] The SC system 100 increases distributed processing capabilities using wireless capabilities. The SC system 100 can be easily installed on the vehicle wiring harness 105 and can reduce downtime due to the wireless connection 110 providing remote monitoring of one or more vehicle parameters (e.g., the oil level of the engine). The wireless connection 110, which may include Bluetooth, WiFi, cellular, or any other suitable telematics or wireless connection, provides real-time information to the user. For example, electronically monitoring the oil level can reduce or prevent the vehicle driver from manually checking the oil. When, for example, an oil overflow event or a low oil level event has been detected, the connector assembly 102 can transmit a signal to alert the user. The user can also track the fuel consumption of the prime mover and improve cost savings by ensuring that the vehicle has the proper oil level. Another potential advantage is that high fuel consumption problems can be solved immediately, rather than after a problem related to a low oil level occurs.

[0028] The connector assembly 102 can be attached to the vehicle wiring harness at various locations on the vehicle, allowing for shorter installation and repair times. The connector assembly 102 can communicate wirelessly with the vehicle driver and / or maintenance operations via Bluetooth, WiFi, cellular, or other suitable wireless and / or telematics connections, and perform additional electronic operations. For example, electronic oil level monitoring to determine oil filter life, calculate oil drain intervals, or monitor tire pressure can be performed by the connector assembly 102.

[0029] The SC system 100 can be used with, for example, In one embodiment, the mechanical interface and pin configuration on the locking mechanism complement the Quick Disconnect HDP26-18 Connector. However, it should be understood that the system 100 may mate and / or complement any type of connector and / or disconnect device.

[0030] The SC system 100 can be attached to the vehicle wiring harness anywhere on the vehicle, thereby providing shorter installation and maintenance time. The SC system 100 can communicate with the vehicle driver, customer and / or maintenance personnel via Bluetooth, WiFi, cellular or any suitable wireless or telematics connection and perform other electronic functions. For example, some other electronic functions may include electronic oil level monitoring, determining oil filter life, calculating oil drain interval (ODI), and tire pressure monitoring.

[0031] Various aspects of the present disclosure are contemplated. According to one aspect, an apparatus includes a connector assembly. The connector assembly includes a base, wherein the base includes an embedded PCB and a plurality of signal pins that electrically couple the PCB to a vehicle wiring harness. The connector assembly also includes a mating connector for mechanically coupling the connection assembly to the vehicle wiring harness and a releasable connection between the mating connector and the base. The releasable connection preloads and axially secures the base to the mating connector.

[0032] In one embodiment, the releasable connection is provided by a spring. In a refinement of this embodiment, the spring is a wave spring washer.

[0033] In another embodiment, the mating connector is configured to lock with the vehicle wiring harness. In yet another embodiment, the vehicle wiring harness is connected to an oil level sensor. In a further embodiment, the connector assembly further includes an insulator between the base and the mating connector, and the insulator is configured to receive the plurality of signal pins therefrom.

[0034] In one embodiment, there is a wireless connection between the connector assembly and the plurality of receivers. In a refinement of this embodiment, the wireless connection is one or more of a Bluetooth connection, a WiFi connection, and a cellular connection. In another embodiment, the base defines a plurality of axially extending channels that receive the plurality of signal pins.

[0035] In yet another embodiment, the base includes a circumferential groove and the mating connector includes an inner radial groove aligned with the circumferential groove to receive therebetween a spring washer forming at least a portion of the releasable connection. In a refinement of this embodiment, the base includes a first body portion that houses the PCB, a second body portion that extends axially from the first body portion, and a third body portion that extends axially from the second body portion, and the mating connector is positioned around the second body portion and the third body portion. In a further refinement of this embodiment, the third body portion has a reduced diameter compared to the second body portion, and the third body portion includes a plurality of axially extending ribs extending along an outer surface of the third body portion. In a further refinement, the third body portion includes a radially extending flange that protrudes outwardly from the outer surface of the third body portion, the flange and the second body portion defining a circumferential groove therebetween for receiving the spring washer.

[0036] In another aspect of the present disclosure, a system is provided. The system includes a connector assembly, the connector assembly including a base. The base includes an embedded PCB and a plurality of signal pins that electrically couple the PCB to a vehicle wiring harness. The connector assembly also includes a mating connector for mechanically coupling the connector assembly to the vehicle wiring harness and a releasable connection between the mating connector and the base. The releasable connection preloads and axially secures the base to the mating connector. The system also includes at least one receiver and a wireless connection between the connector assembly and the at least one receiver.

[0037] In one embodiment, the releasable connection is provided by a spring, such as a wave spring washer. In another embodiment, the mating connector is configured to lock with the vehicle wiring harness, the vehicle wiring harness being configured to connect to an oil level sensor. In another embodiment, the connector assembly further comprises an insulator between the base and the mating connector, the insulator being configured to receive a plurality of signal pins therefrom.

[0038] In another embodiment, the wireless connection includes one or more of a Bluetooth connection, a WiFi connection, and a cellular connection. In yet another embodiment, the base defines a plurality of axially extending channels that receive the plurality of signal pins, and includes a first body portion that accommodates the PCB, a second body portion that extends axially from the first body portion, and a third body portion that extends axially from the second body portion, and the mating connector is positioned around the second body portion and the third body portion. In yet another embodiment, the base includes a circumferential groove, and the mating connector includes an inner radial groove aligned with the circumferential groove to receive a spring washer therebetween that forms at least a portion of the releasable connection.

[0039] Although the present invention has been described in conjunction with what are currently considered to be the most practical and preferred embodiments, it should be understood that the present invention is not limited to the disclosed one or more embodiments, but on the contrary, the present invention is intended to cover various modifications and equivalent arrangements included in the spirit and scope of the appended claims, and the scope of the appended claims will be given the broadest interpretation, so as to cover all such modifications and equivalent structures permitted under the law. In addition, it should be understood that although the words "preferable", "preferably" or "preferred" are used in the above description to indicate that the described feature may be more desirable, it may not be necessary, and any embodiment lacking the feature can be conceived as within the scope of the present invention, the scope of which is defined by the appended claims. When reading the claims, when words such as "one", "a kind", "at least one" or "at least a portion" are used, it is not intended to limit the claim to a single item, unless otherwise clearly stated to the contrary in the claim. In addition, when the language "at least a portion" and / or "a portion" is used, the item may include a portion and / or the entire item, unless otherwise clearly stated to the contrary.

Claims

1. An intelligent connector system, comprising: a vehicle wiring harness for connecting to a device in the vehicle that collects data; as well as A connector assembly comprising a printed circuit board electrically coupled to the vehicle wiring harness to receive vehicle parameter data collected by the device of the vehicle collecting data, wherein the connector assembly comprises a wireless connection for transmitting data signals of the vehicle parameter data in real time to one or more users or remote systems for remote monitoring of the vehicle parameter data.

2. The system of claim 1, wherein the device of the vehicle that collects data is a sensor of the vehicle.

3. The system of claim 1, wherein the one or more users or remote systems include an engine control unit of the vehicle.

4. The system of claim 1, wherein the one or more users or remote systems include a service department for servicing the vehicle.

5. The system of claim 1, wherein the one or more users or remote systems include a driver of the vehicle.

6. The system of claim 1, wherein the vehicle parameter data includes at least one of oil level, filter life, oil change interval, and tire pressure.

7. The system of claim 1, wherein the wireless connection comprises a Bluetooth connection.

8. The system of claim 1, wherein the wireless connection comprises one of a WiFi connection and a cellular connection.

9. The system of claim 1, wherein the connector assembly comprises: a base and the printed circuit board embedded in the base; an insulator mounted to the base; a mating connector releasably mounted to the base, wherein the insulator is between the base and the mating connector, wherein the mating connector is releasably coupled to the vehicle wiring harness; as well as A plurality of signal pins electrically couple the printed circuit board to the vehicle wiring harness, the plurality of signal pins extending through the insulator and the base to electrically connect a plurality of electrical contacts of the printed circuit board to the vehicle wiring harness.

10. The system of claim 1, wherein the connector assembly comprises: a mating connector for connecting to the vehicle wiring harness; a base for receiving the printed circuit board, wherein the base is releasably secured to the mating connector; as well as A plurality of signal pins extend through the base and the mating connector and electrically connect the printed circuit board to the vehicle wiring harness.

11. The system of claim 1 , wherein the connector assembly further comprises a mating connector for mechanically coupling the connector assembly to the vehicle wiring harness, and a releasable connection between the mating connector and a base housing the printed circuit board, wherein the releasable connection preloads and axially secures the base to the mating connector.

12. The system of claim 11, wherein the releasable connection comprises a wave spring washer received in aligned slots and grooves of the mating connector and the base.

13. An intelligent connector system, comprising: a vehicle wiring harness for connecting to a device in the vehicle for collecting vehicle parameter data; a mating connector mechanically coupled to the vehicle wiring harness; a base including an embedded printed circuit board and a plurality of signal pins, wherein the plurality of signal pins electrically couple the printed circuit board to the vehicle wiring harness; a releasable connection between the mating connector and the base; at least one remote receiver; as well as A wireless connection with respect to the at least one receiver is used for transmitting the vehicle parameter data in real time for remote monitoring of the vehicle parameter data.

14. The system of claim 13, wherein the device of the vehicle that collects vehicle parameter data is a sensor.

15. The system of claim 13, wherein the wireless connection comprises one or more of a Bluetooth connection, a WiFi connection, and a cellular connection.

16. The system of claim 13, wherein the at least one receiver comprises at least one of an engine control unit of the vehicle, a service department for servicing the vehicle, and a driver of the vehicle.

17. The system of claim 13, wherein the vehicle parameter data includes at least one of oil level, filter life, oil change interval, and tire pressure.

18. The system of claim 13, wherein the base includes a circumferential groove and the mating connector includes an inner radial groove aligned with the circumferential groove to receive a spring washer therebetween forming at least a portion of the releasable connection.

19. The system of claim 13, further comprising an insulator including a plurality of channels for receiving corresponding ones of the plurality of signal pins, wherein the insulator is positioned between the base and the mating connector.

20. An intelligent connector system, comprising: a plurality of sensors for data collection associated with the operation of the engine; as well as A connector assembly is provided for receiving data collected by the plurality of sensors and communicating with one or more users or remote systems, the connector assembly including a wireless connection for communicating with the plurality of sensors, the connector assembly also including a printed circuit board electrically coupled to a wiring harness.

Images