Electrical connector with transparent area and corresponding inspection station

Abstract

The present disclosure provides "Electrical connectors with transparent regions and corresponding inspection stations." An electrical connector assembly includes a plug and a receptacle each having a mating arm, a retainer, and a light pipe enclosed within a housing having opposing light-transmissive windows. When mated, the plug and receptacle align their light pipes to allow light transmission from a single source. An inspection station secures the connectors using a clamp and optical sensors positioned to view the interior regions through the windows. A light source illuminates the interior regions, and a processor analyzes the sensor data to determine the connection status.

Description

Technical Field

[0001] This disclosure relates to automotive electronic devices. Background Technology

[0002] Vehicles contain electronic systems that manage everything from propulsion to infotainment and driver assistance features. These systems include a network of electronic control units (ECUs) that serve as the computing backbone for various subsystems. Each ECU is responsible for specific tasks, such as transmission management, braking, and climate control. These ECUs communicate with each other via data buses such as Controller Area Network (CAN), Local Area Network (LIN), or Ethernet, enabling real-time data exchange.

[0003] Electrical wiring in a vehicle serves as a looping system distributing power and data signals between the ECU, sensors, actuators, and user interface. Wiring harnesses are designed to manage both power distribution and communication, encompassing multiple voltage levels depending on system requirements. The standard 12V system remains dominant for most vehicle functions, while 48V systems are increasingly used in hybrid and electric powertrains to support higher power loads. High-voltage systems, typically exceeding 400V or even 800V, are dedicated to propulsion and battery management in electric vehicles. Wiring harnesses are laid throughout the vehicle. Shielding techniques (including braided or foil-wrapped conductors) are commonly used in high-frequency signal lines to prevent signal degradation caused by electromagnetic interference. Summary of the Invention

[0004] An electrical connector assembly includes a plug and a socket, each comprising an engagement arm, a retainer, and a light tube enclosed within a housing having opposing windows transparent to certain wavelengths of light, such as ultraviolet light. The plug includes pins held within the plug housing by the engagement arm and retainer, while the socket includes jacks similarly fixed within the socket housing. The plug and socket light tubes are aligned when mated to allow light to be transmitted from a single source through both components. Windows flush with the housing surface and aligned with overlapping areas of the engagement arm and retainer enable optical inspection or signal transmission. The light tubes may be positioned between multiple rows of pins or jacks or adjacent to the housing, which may be constructed of white resin to achieve light reflection.

[0005] An electrical connector assembly inspection station includes a clamp and optical sensors designed to secure and inspect the electrical connector assembly using a housing with light-transmitting window areas. The sensors are positioned between the clamp and the assembly, arranged to observe and directly contact internal areas through these windows. A light source, including an ultraviolet option, illuminates the internal areas of the connector or a light tube. The system may further include a processor programmed to determine the connection status based on sensor data, optionally using a machine learning or artificial intelligence model.

[0006] An assembly includes an electrical connector with a housing having a region that is transparent to ultraviolet light but opaque to visible light, and the assembly includes at least one optical tube. The connector may include male and female components, wherein the optical tube is configured to transmit light across the interface of these components when mated, thereby enabling optical communication or inspection through the UV-transparent region. Attached Figure Description

[0007] Figure 1 This is a cross-sectional side view of the electrical connector before assembly.

[0008] Figure 2 yes Figure 1 The electrical connector is shown in a cross-sectional side view after assembly.

[0009] Figure 3 yes Figure 2 A cross-sectional side view of the electrical connector within the optical inspection unit.

[0010] Figure 4A and Figure 4B These are the plan view and side view of the assembled electrical connector. Detailed Implementation

[0011] Detailed embodiments of this disclosure are provided herein. However, these embodiments are merely examples and may be implemented in various alternative forms. The drawings are not necessarily drawn to scale, and certain features may be enlarged or minimized to highlight specific details of particular components. Therefore, the structural and functional details described should not be construed as limiting, but rather as illustrative examples to guide those skilled in the art in applying the principles described in different embodiments.

[0012] Electrical connectors play a crucial role in facilitating connections between wire harnesses and electronic components. Connector housings are sometimes made of highly durable thermoplastics, while the internal terminals can be constructed from highly conductive metals such as copper or copper alloys and surface-treated (e.g., tin-plating, silver-plating, or gold-plating) to enhance corrosion resistance and electrical performance. Sealing mechanisms, such as rubber gaskets or gel-filled cavities, are incorporated into connectors used in certain compartment or chassis locations to prevent water and dust contamination. Locking features, including auxiliary locking mechanisms and terminal position protection elements, help prevent detachment.

[0013] The proposed connector technology includes one or more transparent or semi-transparent windows integrated into the connector housing for visual inspection of internal components after the connector halves have mate. In some embodiments, this is achieved via a two-shot molding process, in which transparent portions capable of transmitting visible or ultraviolet (UVA) light are strategically placed within the connector housing. These transparent windows allow for real-time observation of terminal alignment, potential terminal ejection, and proper engagement of the locking mechanism without disassembly.

[0014] Example materials include optical-grade polymers such as acrylic (PMMA), polyethylene (PE), or other materials optimized for light transmission. When UVA light is used, the selected material should exhibit transparency within a specific wavelength range while maintaining sufficient mechanical integrity. The connector shell itself may be made of white resin instead of the conventional gray resin to enhance internal light reflection and visibility through the transparent portions. Additionally, optical-grade silicone can be used for seals and locking plugs to maintain transparency and flexibility.

[0015] To facilitate illumination within the connector, light guides are integrated into locations that direct visible or UVA light from external sources through the housing. These light guides ensure illumination reaches the inspection area, eliminating shadows and enhancing contrast for visual or automated inspections. The light guides can be positioned along the perimeter of the connector housing, with dedicated entry points at the connector ends for connecting external light sources. The light guides can be molded into the housing structure, extending parallel to multiple rows of terminals to ensure uniform light distribution throughout the internal cavity.

[0016] The specific placement of the light tube may include: Entry points at the connector interface: The light tube can be positioned near the connector's connection interface, where an external illumination module can inject light into the light tube. These entry points can be designed with a reflective coating to maximize light capture.

[0017] Peripheral setup: The light tube can be embedded along the outer shell layer to direct light to the transparent window while preventing direct glare from entering the camera system.

[0018] Terminal block integration: Light tubes can be designed to follow the internal layout of the terminal block, extending in parallel to prevent obstruction while providing consistent illumination.

[0019] Lighting for locking mechanisms: Dedicated light tubes can direct light specifically to the locking mechanism.

[0020] For inspection and verification, a camera system can be positioned to capture internal components from multiple angles. The camera assembly is mounted within a fixture that holds the connector in place for repeatable imaging. The inspection system can utilize algorithms such as artificial intelligence (AI) and machine learning (ML) to analyze the captured images, thereby detecting misalignment, bent terminals, and incorrect locking engagements. By using UVA illumination and appropriate filters, the system can increase contrast and highlight potential defects that might not be easily visible under standard lighting.

[0021] The terminal arrangement within the connector can be designed with visibility in mind, ensuring critical areas remain unobstructed when viewed through a transparent window. Internal components can be positioned to minimize obstruction and allow for comprehensive inspection from multiple perspectives. Particularly in the locking area, the two halves of the connector can be constructed from contrasting materials to further distinguish between the engaged and disengaged states.

[0022] In one example, a connector assembly includes interconnected components arranged to facilitate both electrical interconnection and visual inspection of internal terminal engagement. The connector housing is an elongated, multi-part shell designed to receive and hold multiple electrical terminals in a fixed arrangement. A double-shot molded transparent window is centrally positioned along the longitudinal axis, allowing external visual or optical inspection systems to assess terminal integrity after mating. The housing may be made of a white resin material to enhance the reflection of light introduced into the interior.

[0023] The locking mechanism includes a set of locking pins arranged within the connector housing to form a secure mechanical engagement between mating connector halves. These locking pins can be formed or shortened using a two-shot molding process to allow light transmission through the structure. Their placement within the connector is feature-aligned with the terminals, thereby ensuring full terminal engagement when the connector is locked.

[0024] Seals made of optical-grade silicone are positioned at designated locations within the housing to provide environmental robustness while allowing light to pass through. These seals are molded to maintain a tight interface between the mating halves while preserving the necessary optical clarity for inspection purposes. The flexible nature of optical-grade silicone allows the sealing elements to conform to structural variations of the connector without impairing visibility.

[0025] The light tube extends into the back portion of the connector housing, thus forming an optical transmission path for light injection. This light tube guides illumination from an external light source located at the rear of the connector. The length and curvature of the light tube can be adapted to accommodate spatial constraints and facilitate alignment between the light source and the internal transparent portion of the connector housing. The injected light propagates through the internal structure, reflects off the white resin wall, and illuminates the inspection area visible through the transparent window.

[0026] The internal terminal arrangement includes conductive elements that are held in place within the connector housing. Structural features align these terminals within designated channels to ensure proper electrical contact when mating with the corresponding connector halves. Transparent windows and light guide paths allow optical inspection systems to detect terminal misalignment, ejection defects, or incorrect engagement of the locking mechanism.

[0027] In the assembled configuration, light enters through a designated light tube, propagates through the housing, and reflects from the inner surface toward the transparent viewing window. The transmitted illumination highlights the position of the terminals and locking components, allowing for verification of their alignment without disassembly.

[0028] In some examples, the inspection assembly includes a fixture, camera chip, and associated optical components arranged around the connector to facilitate multi-angle inspection of the internal terminal arrangement. The fixture structure consists of two opposing portions located on either side of the connector, each extending around the periphery of the connector housing. The fixture is designed to hold the connector in a fixed orientation, preventing movement during inspection. The choice of material for the fixture provides structural rigidity while allowing for alignment of the integrated optical components. The inner surface of the fixture may include recesses or contours shaped to match the external geometry of the connector, providing a stable interface that holds the assembly in place without applying excessive force.

[0029] Camera chips are placed within a fixture structure and oriented to capture multiple views of the transparent portion of the connector. The camera chips are arranged at different locations along the longitudinal axis of the connector, with at least one camera chip located on the top side and one on the bottom side, and possible additional cameras located on opposite lateral sides. This configuration allows the cameras to capture images from different angles to detect variations in terminal placement and any possible misalignment. Each camera chip is integrated with an optical module comprising a lens designed to focus light through the transparent portion of the connector. Optics are selected based on focal length and field-of-view requirements to provide an accurate representation of terminal alignment within the housing.

[0030] The optical components associated with each camera include lenses mounted within the housing and positioned to direct light toward a transparent portion of the connector. Depending on the spectral properties of the light used for illumination, these lenses may contain coatings to reduce glare or enhance contrast. The positioning of the optical elements within the fixture aligns the line of sight of each camera with the region of interest inside the connector. The optical path may also include filters designed to enhance detection of specific wavelengths when using ultraviolet or other invisible light sources.

[0031] The entire fixture, camera, and optics assembly are arranged to maintain consistent positioning of all components relative to the connector. The rigid structure of the fixture stabilizes the camera while allowing the light transmission path to remain unobstructed. This design allows each camera to acquire high-resolution images of the internal terminals from multiple perspectives, enabling the inspection system to detect any misalignment, incorrect engagement, or mechanical displacement within the connector assembly.

[0032] In some implementations, ML or AI models capable of analyzing images, recognizing patterns, and classifying structural problems can be used to detect misalignment, incorrect engagement, or mechanical displacement in connector assemblies. Convolutional Neural Networks (CNNs) are particularly well-suited for this task due to their spatial hierarchical structure, which allows them to extract features from images. A CNN trained on high-resolution images of correctly and incorrectly engaged connectors can distinguish subtle positional variations in terminal alignment. The model processes the input image through multiple layers, including convolutional layers for detecting edges and textures, pooling layers for reducing dimensionality while preserving key features, and fully connected layers that ultimately determine whether the connector exhibits misalignment or displacement. By training the CNN with different datasets that incorporate variations in lighting, viewpoint, and potential defects, the model achieves robustness in detecting inconsistencies across different samples.

[0033] Transformer-based visual models, such as the Visual Transformer (ViT), offer an alternative approach by leveraging multiple mechanisms to analyze relationships between different regions of an image. Unlike CNNs, which focus on local feature extraction, ViTs holistically evaluate the entire image, allowing them to detect subtle deviations that might not be noticeable when only a small portion of the image is examined. The model divides the image into patches, processes each patch through multiple head layers, and builds an understanding of the global and local structural integrity of the connector. ViTs' ability to handle spatial dependencies across the entire image makes them not only well-suited for identifying terminal misalignment but also for identifying deformations in locking mechanisms or variations in the engagement of connector halves.

[0034] Especially when labeled data is limited, problem detection techniques using unsupervised learning models can provide an additional layer of analysis. An autoencoder (i.e., a neural network designed to represent what it has learned) can be trained on images of correctly assembled connectors to create compressed feature representations. During inference, as an image of a potentially misaligned connector passes through the trained autoencoder, the reconstruction error provides an indication of whether the connector differs from the learned normal pattern. High reconstruction errors indicate deviations, which may correspond to incorrect joining or mechanical displacement. Similarly, problem detection can be performed using generative adversarial networks (GANs) by training a generator-discriminator pair, where the discriminator learns to distinguish correctly aligned connectors from defective ones based on subtle variations.

[0035] Traditional computer vision techniques enhanced by ML models can also aid in the inspection process. Edge detection algorithms (such as Canny edge detection) combined with feature-based ML classifiers (such as Support Vector Machines (SVM) or Random Forests) can process grayscale images and extract geometric relationships between connector components. These methods can highlight misaligned terminals by analyzing contour variations or detecting gaps indicating incorrect engagement. By feeding these extracted features into a classifier, decisions can be made about whether the connector assembly is correctly aligned or whether intervention is needed. The integration of classical computer vision with ML allows for interpretable decision-making while maintaining the adaptability of AI-driven approaches.

[0036] Reinforcement learning can be used in active inspection systems where an AI agent learns optimal strategies for locating the camera and adjusting lighting conditions to maximize defect detection accuracy. By modeling the inspection process as a decision-making exercise, the reinforcement learning agent improves its approach through trial and error, selecting perspective and focus adjustments that enhance the visibility of misalignments or shifts. This method is particularly useful in dynamic manufacturing environments where lighting and orientation conditions can change between inspections.

[0037] refer to Figure 1 and Figure 2 The connector assembly 10 includes a male connector 12 and a female connector 14. The male connector 12 includes a pin 16, an engagement arm 18, and a retainer 20 housed within a connector shell or housing 22. The pin 16 protrudes through the retainer 20 and is held in place by the engagement arm 18, which acts as a primary locking feature, and the retainer 20, which acts as an auxiliary lock or terminal position guarantee (TPA) element. During assembly, inserting the pin 16 into its corresponding position (from left to right relative to the drawing) causes the engagement arms 18 to deflect outward until they snap onto a shoulder or crossbar formed on the pin, thereby securing them in place. The retainer 20 is then inserted, preventing the arm 18 from moving and locking the pin 16 to prevent disengagement.

[0038] The female connector 14 includes mating sockets 24, engagement arms 26, and retainers 28, all housed within the housing 30. The sockets 24 are also held by a locking system comprising the arms 26 and the retainers 28. When the sockets 24 (from right to left) are inserted into the housing, the engagement arms 26 bend outwards until they snap into corresponding pawls on the sockets 24, thus locking them in place. The retainers 28 then secure the arms 26, thus maintaining proper engagement of the sockets.

[0039] Misalignment between the male connector 12 and the female connector 14 during mating (such as incomplete pin insertion, partial terminal engagement, or terminal disengagement) may lead to electrical connection degradation or signal loss. Additionally, engagement failure may occur between the locking arms 18, 26 and their corresponding retainers 20, 28, thereby affecting the mechanical integrity of the connector assembly 10.

[0040] The housing 22 of the male connector 12 includes a strategically placed inspection window 32, formed of a transparent or translucent material (such as optical-grade acrylic or polyethylene) and flush with the adjacent surface. The window 32 is produced via a two-shot molding process, integrating the transparent material within the otherwise opaque housing. The window 32 is aligned in its relative position and positioned to allow optical access to the overlapping area between the engagement arm 18 and the retainer 20. This allows for visual or automated inspection of the terminal engagement, retention, and locking engagement—even after the male connector 12 and female connector 14 are fully mated. A light tube 34 is embedded along the housing 22 to guide light (e.g., visible light or UVA wavelength) through the window 32 to illuminate internal components. The light tube 34 can be coupled to an external light source and may have a reflective coating to maximize internal light transmission. Alternative placements of the light tube 34 are shown in dashed lines.

[0041] Similarly, housing 30 includes a transparent window 36, which is similarly formed and aligned to provide a viewing path to the engagement interface between engagement arm 26 and retainer 28. Female connector 14 also includes a light guide 38 extending through or adjacent to housing 30 to uniformly illuminate the internal locking features. Like male connector 12, light guide 38 may include reflective or refractive features to enhance visibility. These transparent areas and light guide paths are designed to facilitate both manual inspection and automated machine vision inspection.

[0042] refer to Figure 3 The inspection station includes a fixture or clamp 40, a set of optical sensors 42 (e.g., a camera module), an external light source 44, and a processor 46. The clamp 40 holds the mating connector assembly 10 in a fixed and repeatable position. The optical sensors 42 are arranged at multiple angles (top, bottom, and sides) to view the transparent windows 32, 36 from different perspectives. When activated, the light source 44 injects light into the light tubes 34, 38, thereby filling the interior of the connector with light and enhancing contrast in the inspection area. The sensors 42 capture image or video data, which is then sent to the processor 46.

[0043] Processor 46 can execute one or more computer vision algorithms or ML models designed to detect connector defects such as misaligned terminals, incomplete insertion, incorrect locking, or terminal ejection. These algorithms can include conventional image processing techniques, as well as supervised and unsupervised learning methods trained on large datasets of connector images.

[0044] Processor 46 can employ classic computer vision techniques (such as Canny edge detection, Sobel filters, or Laplacian operators) to extract geometric boundaries from the regions visible through windows 32, 36. This preprocessing step facilitates downstream analysis by recognizing the contours of pin 16, socket 24, engagement arm 18, and retainer 28. Once the edge map is generated, processor 46 can compare the resulting geometry with a stored reference model to detect structural deviations, such as terminal offset, tilt, or partial insertion depth. Contour-based shape descriptors (e.g., Hu moments) or histogram-based features (e.g., HOG) can further support classification tasks.

[0045] The extracted features (e.g., pixel intensity, geometric descriptors, local binary patterns) can be used to train ML models such as Support Vector Machines (SVM), Random Forests, or k-Nearest Neighbors (k-NN) classifiers. The model is trained on a labeled dataset containing images of correctly assembled connectors and various conditions (e.g., terminals not fully inserted, locks not engaged, terminals rotated). Training can be performed offline using various datasets of connector assemblies captured under different lighting conditions, orientations, and manufacturing tolerances. The trained classifier can then be deployed to processor 46 for real-time inference at the inspection station.

[0046] In more advanced configurations, processor 46 can use CNNs to automatically learn the spatial hierarchy of visual features. The CNN-based model can include multiple convolutional and pooling layers, followed by a fully connected layer whose output is a classification score indicating whether the connector assembly 10 is "OK" (normal) or exhibits a defect. The CNN architecture, such as ResNet, MobileNet, or EfficientNet, can be chosen based on the computational resources available at the checkpoint. The model can be trained on thousands of labeled images of the connector assembly under controlled lighting, where ground-based labels indicate the presence or absence of a specific type of mechanical or electrical fault.

[0047] As an alternative to CNN, processor 46 can use a transformer-based vision model that segments each image into patches and uses multi-head techniques to evaluate spatial relationships between features. ViT is able to detect subtle and distributed problems across connector assembly 10, such as small-scale displacement of terminal positions or gradual deformation of the locking mechanism.

[0048] In applications where labeled fault data is limited, unsupervised models, such as autoencoders, can be used to detect outliers. An autoencoder trained only on images of correctly assembled connectors learns a compact latent representation of the normal appearance. When a defective image passes through the autoencoder, a high reconstruction error in a specific region (e.g., the locking region) indicates a deviation from the norm. Similarly, GAN-based methods can train a discriminator to distinguish between genuine "OK" images and synthesized examples, thereby learning to identify structural anomalies without explicit defect labels.

[0049] In some embodiments, the inspection station may include an adaptive camera positioning system that uses reinforcement learning to dynamically optimize the viewpoint, focus, and illumination. Trial-and-error interaction can be used to train the policy network to maximize defect detection confidence, allowing the system to automatically reposition the optical sensor 42 based on the physical layout of the connector assembly 10 and real-time feedback from inspection results.

[0050] For robust algorithm performance, a comprehensive dataset is helpful. This dataset can include images of connectors with varying numbers and types of defects (e.g., terminal pull-out, partial insertion, pin bending, misalignment), variations in lighting, angle, and housing translucency, as well as connector samples from multiple production batches (to account for manufacturing tolerances).

[0051] The labeled dataset can be managed using manual annotation, semi-automated labeling tools, or digital twins that simulate the expected connector states. Data augmentation techniques, such as random rotation, scaling, or brightness adjustment, can be used to expand the training data for generalization. If bounding box localization is required, the model can be validated using precision-recall curves, confusion matrices, or inter-overlap (IoU) scores.

[0052] Once trained and validated, the model can be deployed in an embedded computing environment associated with processor 46. Real-time inference can be performed using optimized runtimes such as TensorRT or ONNX runtimes to deliver deterministic performance in high-throughput production lines.

[0053] refer to Figure 4A and Figure 4BAnother example connector assembly 110 is shown in top and side views, respectively. Male connector 112 and female connector 114 are structurally and functionally similar to the connectors described above. Male connector 112 includes a housing 122 with an inspection window 132 through which the engagement arm 118 and retainer 120 are visible. Female connector 114 includes a housing 130 with a window 136 allowing observation of the engagement arm 126 and retainer 128. These connectors demonstrate external visibility of the retaining features from different orientations, enabling multi-angle inspection and providing a means for automated in-line inspection in production environments.

[0054] The algorithms, methods, and processes described herein can be delivered to or implemented by a computer, controller, or processing device (such as processor 46), including a dedicated or programmable ECU. These algorithms, methods, and processes can be stored in various formats as data and executable instructions, such as information permanently stored on a non-writable storage medium (e.g., a read-only memory device) or information reproducibly stored on a writable storage medium (e.g., an optical disc, random access memory, or other magnetic and optical media). They can also be implemented as software executable objects. Alternatively, these algorithms, methods, and processes can be implemented partially or entirely by hardware components such as application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), state machines, or other suitable hardware devices. In some cases, these functions can be implemented using a combination of firmware, hardware, and software components.

[0055] While the above example embodiments illustrate various implementations, they do not cover all possible forms of the disclosed subject matter. The language used in this specification is descriptive rather than restrictive, and it should be understood that modifications can be made without departing from the scope and basic principles of this disclosure. Furthermore, features from different embodiments can be combined to create additional variations.

[0056] According to the present invention, an electrical connector assembly is provided, the electrical connector assembly comprising: a plug including: pins; a plug engagement arm configured to hold the pins in place; a plug retainer configured to restrict movement of the plug engagement arm; a plug light tube; and a plug housing, the plug housing at least surrounding the plug engagement arm and the plug retainer and defining plug windows aligned on opposite sides of the plug housing, the plug windows being transparent to light of at least some wavelengths; and a socket including: a socket; a socket engagement arm configured to hold the socket in place; a socket retainer configured to restrict movement of the socket engagement arm; a socket light tube; and a socket housing, the socket housing at least surrounding the socket engagement arm and the socket retainer and defining socket windows aligned on opposite sides of the socket housing, the socket windows being transparent to light of at least some wavelengths.

[0057] According to one embodiment, the plug light tube and the socket light tube are positioned such that when the plug and the socket are engaged, the ends of the plug light tube and the socket light tube are aligned to allow light from one of the plug light tube or the socket light tube to be transmitted to the other, such that a single light source can illuminate both the plug light tube and the socket light tube.

[0058] According to one embodiment, the plug window and socket window are transparent to ultraviolet light, but opaque to visible light.

[0059] According to one embodiment, the pins are arranged in rows, and the plug light tube is positioned between the rows.

[0060] According to one embodiment, the plug light tube is positioned adjacent to the plug housing.

[0061] According to one embodiment, the plug window is further aligned with the overlapping area of ​​the plug engagement arm and the plug retainer.

[0062] According to one embodiment, the plug window is flush with an adjacent portion of the plug housing.

[0063] According to one embodiment, the sockets are arranged in rows, and the socket light tubes are positioned between the rows.

[0064] According to one embodiment, the socket light tube is positioned adjacent to the socket housing.

[0065] According to one embodiment, the socket window is further aligned with the overlapping area of ​​the socket engagement arm and the socket retainer.

[0066] According to one embodiment, the socket window is flush with an adjacent portion of the socket housing.

[0067] According to one embodiment, the plug housing and the socket housing comprise white resin.

[0068] According to the present invention, an electrical connector assembly inspection station is provided, the inspection station comprising: a clamp and an optical sensor configured to hold an electrical connector assembly therein, the electrical connector assembly including at least one housing defining a window region transparent to light of at least some wavelengths, such that the optical sensor is positioned between the clamp and the electrical connector assembly and is arranged to observe a region inside the electrical connector assembly via the window region; and a light source configured to illuminate the region.

[0069] According to one embodiment, the clamp and the optical sensor are further configured such that the optical sensor contacts the window region.

[0070] According to one embodiment, the invention is further characterized by one or more processors programmed to identify the connection status of the electrical connector assembly based on data from the optical sensor.

[0071] According to one embodiment, the one or more processors are further programmed to implement machine learning or artificial intelligence models to evaluate the data.

[0072] According to one embodiment, the light source is configured as a light tube that illuminates the electrical connector assembly.

[0073] According to one embodiment, the light source is an ultraviolet light source.

[0074] According to the present invention, an assembly is provided having: an electrical connector including a housing defining a region that is transparent to ultraviolet light but opaque to visible light and carrying at least one optical tube therein.

[0075] According to one embodiment, the electrical connector includes a male connector and a female connector, and wherein the at least one optical tube is configured to transmit light across the interface between the male connector and the female connector when the male connector mates with the female connector.

Claims

1. An electrical connector assembly, comprising: A plug, comprising: pins; a plug engagement arm configured to hold the pins in place; a plug retainer configured to restrict movement of the plug engagement arm; a plug light tube; and a plug housing, the plug housing at least surrounding the plug engagement arm and the plug retainer and defining plug windows aligned on opposite sides of the plug housing, the plug windows being transparent to light of at least some wavelengths; and A socket, comprising: a socket; a socket engagement arm configured to hold the socket in place; a socket retainer configured to restrict movement of the socket engagement arm; a socket light tube; and a socket housing, the socket housing at least surrounding the socket engagement arm and the socket retainer and defining socket windows aligned on opposite sides of the socket housing, the socket windows being transparent to light of at least some wavelengths.

2. The electrical connector assembly of claim 1, wherein the plug light tube and the socket light tube are positioned such that when the plug and the socket are mated, the ends of the plug light tube and the socket light tube are aligned to allow light from one of the plug light tube or the socket light tube to pass to the other of the plug light tube or the socket light tube, such that a single light source can illuminate both the plug light tube and the socket light tube.

3. The electrical connector assembly as claimed in claim 1, wherein the plug window and the socket window are transparent to ultraviolet light but opaque to visible light.

4. The electrical connector assembly of claim 1, wherein the pins are arranged in rows and the plug light tube is positioned between the rows.

5. The electrical connector assembly of claim 1, wherein the plug optical tube is positioned adjacent to the plug housing.

6. The electrical connector assembly of claim 1, wherein the plug window is further aligned with the overlapping area of ​​the plug engagement arm and the plug retainer.

7. The electrical connector assembly of claim 1, wherein the plug window is flush with an adjacent portion of the plug housing.

8. An electrical connector assembly inspection station, comprising: A clamp and an optical sensor are configured to hold an electrical connector assembly therein, the electrical connector assembly including at least one housing defining a window region transparent to light of at least some wavelengths, such that the optical sensor is positioned between the clamp and the electrical connector assembly and is arranged to observe a region inside the electrical connector assembly via the window region; and A light source, configured to illuminate the area.

9. The electrical connector assembly inspection station of claim 8, wherein the clamp and the optical sensor are further configured such that the optical sensor contacts the window area.

10. The electrical connector assembly inspection station of claim 8, further comprising one or more processors programmed to identify the connection status of the electrical connector assembly based on data from the optical sensor.

11. The electrical connector assembly inspection station of claim 10, wherein the one or more processors are further programmed to implement machine learning or artificial intelligence models to evaluate the data.

12. The electrical connector assembly inspection station of claim 8, wherein the light source is configured to illuminate a light tube of the electrical connector assembly.

13. The electrical connector assembly inspection station as claimed in claim 8, wherein the light source is an ultraviolet light source.

14. An assembly comprising: An electrical connector comprising a housing defining an area that is transparent to ultraviolet light but opaque to visible light and carrying at least one optical tube therein.

15. The assembly of claim 14, wherein the electrical connector comprises a male connector and a female connector, and wherein the at least one optical tube is configured to transmit light across the interface between the male connector and the female connector when the male connector mates with the female connector.

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