Apparatus, system, computer-implemented method for creating digital twinning of insulated body for connector

Abstract

A digital twinning device (1) for creating an insulated body (2) for a connector using a computer (3) comprising a microprocessor (4), a memory (5), an input interface (6), an output interface (7), a data output interface (8), and a bidirectional data and computer network is described. The memory comprises a computer program product (9) having an interrogation device (10) for technical data of the connector and a CAD design device (11) for the insulating body. This device allows the automatic creation of generative designs of the insulating body (2) using at least one algorithm device (12) and technical data from an interrogation device, and these designs can be output as digital twin from an output device (19) via an interface.

Description

Technical Field

[0001] This invention relates to an apparatus and system for creating a digital twin of the insulating body of a connector, as well as a computer-implemented method. Background Technology

[0002] Insulating bodies for connectors are typically mass-produced using injection molding. Custom connectors, often in smaller quantities, are derived from injection-molded insulating bodies. These are usually larger. This means that not all openings in the insulating body intended for cable connections are used as contacts. There is a possibility of automatically ordering smaller quantities of connector housings according to customer specifications to create and manufacture them based on those specifications. The insulating body is a standard insulating body. Summary of the Invention

[0003] The object of this invention is to provide an apparatus, system, and computer-implemented method for creating digital twins of the insulation body for connectors to increase the flexibility of custom insulation body designs (especially for custom insulation body designs with smaller batch sizes) as part of connectors.

[0004] This objective is achieved through the independent device and method claims. Further embodiments arise from the dependent claims.

[0005] The device described herein, specifically for automatically creating digital twins of the insulation body of connectors, is equipped with a computer comprising: a microprocessor, memory, an interface for input, an interface for screen output, an interface for data output, and a bidirectional data and computing network. The memory includes a computer program product having an interrogation device for technical data of the connector and a CAD design device for the insulation body of the connector. Using the CAD design device, a generative design can be automatically generated based on at least one algorithmic device and technical data from the interrogation device, and the generative design can be output as a digital twin via the output device interface.

[0006] The equipment is designed to query customized technical data regarding the number of connectors, the number of connector contacts, the number of power lines and data lines, and their performance, based on connector requirements. Performance is specified in volts and amperes. Specifications are provided for the contacts where signals are transmitted.

[0007] Therefore, a device has been created that allows for the creation of customer-specific insulation bodies for connectors based on automatically collected technical data, thereby saving resources and ensuring that they are not oversized.

[0008] According to another embodiment, the at least one algorithm device includes at least one algorithm based on the finite element method (FEM) and / or finite element analysis (FEA) and / or an algorithm utilizing an artificial intelligence method with self-learning capabilities and / or neural networks and / or an algorithm for mechanical and / or electrical wiring in CAD applications and / or an algorithm for lightweight construction.

[0009] It should be understood that these lists are not exhaustive, but rather include all known technical methods in the field of construction that form algorithms for automatically generating CAD designs based on given technical constraints and specifications.

[0010] This significantly reduces the cost of custom-designed insulation bodies for a decreasing number of connectors. Therefore, generating a larger number of CAD designs for custom insulation body selection is more cost-effective. Furthermore, resource savings are achieved in terms of materials when they are built on demand.

[0011] Traditionally, custom connectors undergo one or more different operability tests. These tests check whether the insulated body meets required specifications regarding air gaps and creepage distances, pilot contacts, mating and extraction forces, and other tests known in the art, particularly DIN standards. More recently, these tests can also be simulated using appropriate testing equipment.

[0012] For this purpose, the computer program product preferably includes a test device by means of which the discovered generative design of the insulating body can be subjected to at least one of the following tests through simulation: air gap and creepage distance between contacts and / or insertion and extraction force and / or pilot contact.

[0013] Therefore, significant savings in labor, time, and other resources are achieved between the ordering and delivery times for connectors. Connectors can be delivered to customers much faster because the necessary tests have already been performed in simulations. Consequently, actual simulations and tests in the testing lab can be eliminated or reduced to a few random samples.

[0014] According to another embodiment, the device includes a selection device by means of which different designs of the insulating body can be listed according to certain criteria of the sequence, particularly according to criteria of ease of assembly, required space, weight, CO2 cost expenditure, component cost expenditure and / or insertion and extraction force.

[0015] It should be understood that these standards are merely examples and not exhaustive, and may include other standards known in the art. By selecting equipment, customers can thus individually determine the design focus of the insulation body based on specific technical data.

[0016] The insulating body is designed for a connector that functions as both a socket and a plug. Furthermore, to ensure the connector always mates correctly, the device preferably includes means for generating a socket-plug combination with two insulating bodies that have a Poka-Yoke connector. The Poka-Yoke principle means avoiding unexpected errors during the connection process.

[0017] Furthermore, the device preferably includes manufacturing development equipment, by means of which manufacturing data corresponding to the planned manufacturing process can be generated from the product data file of the digital twin of the insulating body. For example, manufacturing data is generated to process the insulating body from raw materials into customized insulating bodies. Alternatively, it is possible to generate 3D printing data, if such insulating bodies are desired, or for larger quantities, injection molding tools can be generated from the product data of the digital twin of the insulating body. The manufacturing development equipment preferably selects an appropriate manufacturing process based on the input desired customized quantity and other specifications of the insulating body, and generates the necessary manufacturing data accordingly, which can then be exchanged via a data interface.

[0018] Furthermore, preferably, the equipment includes a certification device that can issue certification reports on one or more simulations performed on a selected generative design of the insulation body and / or connector. In this way, the simulated test reports can be automatically provided to the customer for custom generative design work, which the customer can rely on when installing these custom connectors in their own custom systems.

[0019] A system for automatically creating a digital twin of the insulating body for a connector is also described, comprising the aforementioned device, wherein a client computer can access and communicate with the device via the device’s network interface, particularly using an Internet connection.

[0020] Furthermore, the online store device is preferably integrated with or communicates with this device, enabling customers with distributed client computers who require customized connectors to digitally connect to a central device. Customers use their client computers to select their desired insulation body from a variety of designs based on their specific technical data. They order the automatically generated and selected insulation body design from their client computers, with corresponding payment processing and settlement preferably handled on the seller's side. Therefore, the process of utilizing this system is significantly simplified and automated, making each step of creating a digital twin of a customized, resource-efficient insulation body for the connector significantly faster.

[0021] According to another advanced system, the aforementioned device is preferably designed as a master device, and the separate, previously described device of the computer program product in the master device is integrated as part of the computer program product on another separate computer, wherein product files and the processing results of the product files are exchangeable between the master device and the other separate computer via a network interface. Therefore, the computationally intensive parts of the computer program product can be retained on the existing device, and third parties can integrate the entire computer program product into the system. This objective is also achieved by a computer-implemented method, particularly by means of the aforementioned device or system, for automatically creating a digital twin of the insulation body for a connector, wherein the computer-implemented method includes: an inquiry step regarding the technical data of the contact connector and the desired number of customized connectors; a step of automatically generating at least one design (preferably another design) of the insulation body by means of an algorithm device based on the CAD design device and the technical data from the inquiry step; and outputting the digital twin of the insulation body as a product data file at a data interface.

[0022] Using a prescribed method, at least one, preferably several, designs for a custom insulating body are efficiently and automatically generated upon customer request. Therefore, previous manual activities are automated and integrated, resulting in a significant reduction in the cost of custom insulating bodies. Furthermore, the time required to create such connectors is greatly reduced.

[0023] The custom insulation body for connectors manufactured using the aforementioned equipment or system in the above-described method offers customization advantages, such as in terms of space or in ensuring functionality through simulations that have been performed efficiently over time.

[0024] A connector having the aforementioned insulating body and housing is also described herein, wherein preferably, the housing and / or insulating body are lockable, each of the housing and / or insulating body being designed as a socket and a plug.

[0025] Furthermore, preferably, the product data file is generated using the aforementioned equipment or system according to the above method. This product data file includes all the technical features expected by the customer and a customer-specific, optimized, automatically generated 3D design of the insulation body, preferably with a matching housing and their connections for cable feeding. The product data file may also include manufacturing process information necessary for machining, injection molding, or 3D printing and the manufacturing tools used.

[0026] This objective is also achieved by a computer program product that can be loaded into the computer memory of the aforementioned device or system to execute the aforementioned methods using code commands.

[0027] Therefore, this objective can also be achieved efficiently and resource-efficiently through a combination of methods that can be combined in individual devices with many standard components. Attached Figure Description

[0028] The invention will now be explained in more detail with reference to exemplary embodiments and the accompanying drawings. The drawings show: Figure 1 This shows a schematic diagram of the device. Figure 2 A schematic flowchart illustrating the computer implementation method of a computer program product is shown. Figure 3 A schematic diagram of the system is shown, and Figure 4 , 5 Figures 6 and 7 show various insulating bodies, each of which is shown in perspective. Detailed Implementation

[0029] Figure 1 A device 1 is shown that has a computer 3 for automatically creating a digital twin of an insulating body 2 for a connector. The computer 3 has a microprocessor 4, a memory 5, an interface 6 for input, an interface 7 for screen output, an interface for data output, and a bidirectional data and computer network 8. The computer memory 5 has computer program products 9, which can be loaded and stored in the memory 5 by code commands.

[0030] Computer program product 9 includes query device 10 and CAD design device 11 with algorithm device 12. Query device 10 is provided to capture technical data for a custom connector with a custom insulating body 2. This technical data includes the required number of insulating bodies, the number of contacts, and the types of contacts for electrical and signal applications. The customer specifies customization requirements to query device 10, including the number and type of contacts for voltage, current, data transmission methods, pneumatics, and the maximum space required.

[0031] The CAD design device 11 includes a CAD design program utilizing an algorithm device 12 based on prior art. This algorithm device 12 generates a generative design using at least one algorithm based on technical data from the query step 10. An example of such a design for the insulating body 2 is shown as a digital twin on a screen 13 connected to the screen output interface 8.

[0032] Further generative design of the insulating body 2 for the connector in Figures 4 to 6 The example is shown below.

[0033] The algorithm device 12 includes algorithms for automatically generating CAD designs based on existing technologies (such as algorithms based on the finite element method (FEM) and / or finite element analysis (FEA) methods), and algorithms using artificial intelligence methods, which may also include self-learning functions or neural networks. The algorithms may also include CAD applications for mechanical and / or electrical wiring, as well as other known algorithms, such as those for lightweight or biomimetic lightweight design. This allows for the automated creation of resource-efficient and material-efficient designs.

[0034] The computer program product includes a selection device 14 that prompts the customer to select a specific design of the insulation body at a control panel via a keyboard 61. This selection can be based on factors such as weight, space, ease of assembly, component cost, and other criteria, such that a list appears on screen 13 in an order of priority depending on the cited criteria.

[0035] Prior to design selection in step S14, a test device 15 is preferably provided, which uses simulation to model at least one generative design to perform various tests on the insulation body, particularly regarding factors such as air gaps and creepage distances between contacts and / or pilot contacts, insertion and withdrawal forces, or thermal management factors. The simulated test results may also be provided in the order list or standards. It should be understood that, in the process flow, the test device 15 may be provided before or after the selection of device 14. Similarly, before or after this, a device, mechanism 16, is provided for generating error-proof connectors to produce socket-plug combinations of two insulation bodies, wherein only the correct connectors can be connected, and the contacts always correctly match each other. This prevents the plug from being inserted backwards into the socket. Alternatively, the contacts in the insulation body may be arranged such that the insulation body can be rotated 180° and still have correct contact matching.

[0036] The device 1 also includes a certification device 17, which generates a certification report on the simulations performed for the protection function, resulting in a shortened type test. This report pertains to the design of the insulation body 2 selected by the customer.

[0037] Optionally, in the next step, manufacturing data is generated by the manufacturing development equipment 18. The type and method of manufacturing are selected based on the previously specified desired quantity of the insulating body 2; for example, processing is conventionally performed for small batch sizes, or injection molding is used for very high quantities, or a special 3D printing process is employed if conditions permit. The manufacturing data is exported from the product data file of the digital twin of the insulating body 2 and digitally appended to the product data file.

[0038] In output device 19, digital data is output to the user or customer in output step 19. Optionally or preferably, this data is forwarded to online store 20, allowing the customer to directly order the custom-designed insulating body along with the connector before the data is handed over to them, and to order all necessary components if required. Online store 20 can be integrated into device 1, or it can be located on a separate online store device as part of system 100.

[0039] Figure 2 A preferred flow is shown of a computer-implemented process, such as that executed by a computer program product 9, when loaded into the program memory 5 of device 1 and run on a computer 3 having a microprocessor 4.

[0040] By using the input interface with keyboard 61, call such as Figure 1 The computer program product in device 1 shown, or as Figure 3 As shown in system 100, when client computer 50 communicates with device 1 via network interface 8, especially via Internet connection 40, it uses call A1 to start computer program product 9, causing query device 10 to perform query step A10 for technical data on contact connection of custom insulating body 2.

[0041] Only after all the necessary data has been fully entered does the process proceed to the next step S11, in which at least one design, preferably multiple designs, of the customized insulating body 2 based on the technical data from the query step 10 are combined with the algorithm from the algorithm device 12.

[0042] In step S15, the functionality of the generative design of the insulation body 2 is checked by simulating various scenarios using test equipment 15. These simulations are known from the prior art and are incorporated herein. Therefore, actual physical inspection is no longer necessary, saving time and resources due to the computer-implemented simulations.

[0043] In selection step S14, a specific design is selected from various designs created by the customer using custom criteria in a specific order, in the selection device 14. These criteria may include space, weight, component cost, or insertion and extraction force, ease of assembly, or other unspecified criteria such as thermal management.

[0044] In step S16, the setting mechanism 16 for generating the error-proof connector creates an error-proof connector for the design of the insulating body 2 selected in step S14, thereby ensuring that there is only one type of socket-plug combination that uniquely connects the two insulating bodies.

[0045] In optional step S17, the certification device 17 generates a certification report, thereby documenting that a defined simulation has been performed according to predefined certification specifications to ensure that customers can trust the specific quality of the connector.

[0046] The manufacturing development equipment 18 can generate manufacturing data for the insulating body 2 and provide specific manufacturing processes in an optional subsequent step S18. Such manufacturing development equipment is known from the prior art. The advantage is that appropriate types of data are immediately available for the generative design of the insulating body 2, thus eliminating the need for manually initiating additional processes. At the end of the process, both the positive part in the form of a digital twin and the corresponding data for manufacturing this twin are available.

[0047] In output step S19, the user receives a digital twin product data file of the connector and custom insulation body in a desired standardized format (which may be proprietary), thereby automating many process steps and many devices of the product through computer programs.

[0048] Optionally, in step S20, the purchase price is allocated to the components, namely the insulating body 2 along with the entire connector, allowing the customer to order the desired quantity of the actual digital twin of the connector and insulating body 2 directly from the online store 20, for example, from their client computer 50 or an employee upon customer request. In this final step, a possible delivery date can be communicated.

[0049] It is important to understand that it is not necessary to include all the steps and devices of a computer-implemented method, but the order and addition of the steps can be changed as needed and are covered by the scope.

[0050] Figure 3 System 100 is shown, which is used to automatically create an insulating body 2 for a connector using device 1 as described above and client computer 50. Each of device 1 and client computer 50 also includes a control terminal 61 with a screen display 13, which is omitted here for simplicity. Client computer 50 is connected to device 1 via network interface 8 and Internet connection 40, thereby allowing them to communicate with each other.

[0051] System 100 includes device 1 as main device 101, on which only a portion of the various steps and devices of the aforementioned computer program product 9 are formed.

[0052] Other parts of the computer program product 9 are outsourced to separate auxiliary computers 60, 70, and are connected and invoked as needed when requested by the main device 101. Therefore, each of these auxiliary computers 60, 70 comprises one or more separate devices of the computer program product 9. These separate devices may be CAD design equipment 11, testing equipment 15, certification equipment, or online store equipment 20.

[0053] Figures 4 to 6 Various views of the insulating body 2 for the connector are shown in perspective, which is created as a digital twin using the device 1 or by means of the system 100 in the form of a product data file.

[0054] The variations of the systems, methods, and apparatus described above are intended only to provide a better understanding of the structure, operation, and features of the presented solutions. They do not limit this disclosure to the described embodiments. The figures are schematic, in which basic features and effects are partially enlarged to illustrate functionality, operating principles, technical configurations, and characteristics. Any operation, principle, technical configuration, or feature disclosed in the figures or text may be freely and arbitrarily combined with all claims, features in the text and other figures, and other functions, principles, technical configurations, and characteristics disclosed in this disclosure, resulting in all conceivable combinations of the described solutions. This also includes combinations between all individual versions in the text (i.e., in each section described), in the claims, and between different versions in the text, in the claims, and in the figures.

[0055] The details of the systems, devices, and methods previously explained are shown in context; however, it should be noted that they are independent of each other and can be freely combined with one another. The relationships between the various parts and components shown in the figures, as well as their dimensions and proportions, should not be construed as limiting. Instead, the dimensions and proportions may deviate from those shown.

[0056] The claims do not limit this disclosure, and therefore, combinations of all the features shown are possible. All the features shown are individually and explicitly disclosed, and can be combined with all other features disclosed herein.

[0057] All figures are shown in schematic, non-scaled representations. Furthermore, special emphasis is placed on the accompanying drawings of the present invention.

Claims

1. Apparatus (1) for creating a digital twin of an insulating body (2) for a connector, said apparatus (1) being configured with a computer (3) comprising a microprocessor (4), a memory (5), an interface (6) for input, an interface (7) for screen output, an interface (8) for data output, and a bidirectional data and computing network, wherein, The memory comprises a computer program product (9) with an interrogation device (10) for technical data of a connector and a CAD design device (11) for an insulation body, by means of which a generative design of the insulation body (2) can be automatically generated on the basis of at least one algorithm device (12) and the technical data from the interrogation device and can be output as a digital twin by an output device (19) via an interface.

2. The apparatus of claim 1, wherein, The at least one algorithm device comprises at least one algorithm based on the finite element method (FEM) and / or finite element analysis (FEA), and / or an algorithm using artificial intelligence methods with self-learning functions and / or neural networks, and / or an algorithm for mechanical and / or electrical wiring of CAD applications, and / or an algorithm for lightweight construction.

3. The apparatus of claim 1 or 2, wherein, The computer program product comprises a testing device (15) by means of which at least one generative design of the insulation body can be subjected to at least one of the following tests by means of simulation: air gap and creepage distance between contact pieces and / or plug-in force and / or premature contact.

4. The apparatus of one of claims 1 to 3, wherein, A selection device (14) is provided by means of which different designs of the insulation body can be listed in a specific order, in particular on the basis of criteria such as ease of assembly, installation space, weight, CO2 costs, component costs and / or plug-in force.

5. The apparatus of one of claims 1 to 4, wherein, The (1) comprises a setting mechanism (16) for generating a socket- plug combination of two insulation bodies with an error-proof plug connection.

6. The apparatus of one of claims 1 to 5, wherein, The device comprises a manufacturing development device (18) by means of which manufacturing data corresponding to a planned manufacturing process can be generated from the product data file of the digital twin of the insulation body.

7. The apparatus according to one of claims 1 to 6, wherein, An authentication device (17) can issue an authentication report on the simulation carried out, which simulation relates to a selected generative design of the connector and / or insulation body.

8. System (100) for creating a digital twin of an insulating body for a connector, the system (100) comprising a device according to one of claims 1 to 7, wherein, A client computer (50) can access the communication with the device via a network interface (8), in particular with an internet connection (40).

9. The system of claim 8, wherein, The device according to one of claims 1 to 7 is designed as a master device, and the above-mentioned individual devices of the master device can be implemented on additional separate computers (60, 70), and product files and processing results of the product files can be exchanged between the master device and the additional computers via a network interface.

10. Computer-implemented method for creating a digital twin of an insulation body for a connector, in particular using a device according to one of claims 1 to 7 or a system according to one of claims 8 or 9, the computer-implemented method comprising: an interrogation step (A10) for technical data on contact connections and a desired number of connectors, a step (S12) for automatically generating at least one design of an insulation body using a CAD design device on the basis of an algorithm device of a design device and the technical data from the interrogation step, and The step of outputting the digital twin of the insulation body as a product data file at the data interface is (S19).

11. An insulating body for a custom connector manufactured using the device according to any one of claims 1 to 7 or the system according to claim 8 or 9.

12. A connector having a custom insulating body and housing according to the preceding claims, wherein the housing is in particular lockable.

13. A product data file generated using the device according to any one of claims 1 to 7 or the system according to claim 8 or 9.

14. A computer program product capable of being loaded into the computer memory of a device according to any one of claims 1 to 7 or a system according to claim 8 or 9 to perform the method according to claim 10.

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