Protection device for connecting part of vehicle wire harness connector

Abstract

The utility model discloses a protection device at the connection part of a vehicle wire harness connector, which aims to solve the problems of poor sealing, weak vibration resistance and no monitoring of the traditional device, and comprises a protection sleeve body, an end cover, a fixed connection column, a monitoring unit and an inner guide sleeve, the protection sleeve body is provided with a containing space, the end covers seal the two ends of the space and prevent impurities from invading through a sealing structure, the fixing connecting columns facilitate device fixing, the inner guide sleeve guides a wire harness and reduces friction, and the monitoring unit comprises a sensor assembly, a data processing unit and an early warning unit and can monitor the temperature, humidity, vibration and contact resistance of a connector in real time. When the threshold value is exceeded, acousto-optic early warning is performed The device is high in adaptability, comprehensive in protection, capable of guaranteeing stable operation of the vehicle wire harness connector, and suitable for various vehicle wire harness protection scenes.

Description

TECHNICAL FIELD

[0001] The utility model belongs to the technical field of vehicle wire harness protection, specifically relates to a protection device for the junction of vehicle wire harness connector, is applicable to the wire harness connector protection scene of all kinds of fuel vehicles and new energy vehicles, especially the wire harness connection protection under the harsh working condition of being vulnerable to high temperature, water vapor, dust invasion and frequent vibration in the engine compartment, chassis and the like, can not only realize the physical protection of the wire harness connector, but also can grasp the connector operation state in real time through the monitoring function, provides the guarantee for the stable operation of the vehicle electrical system, and expands the function dimension of the vehicle wire harness protection device. BACKGROUND

[0002] The traditional vehicle wire harness connector protection device adopts a single sealing structure, such as a simple sealing ring, in a high-temperature environment of an engine compartment, the sealing ring is prone to aging and failure, in a scenario where the chassis is involved in water or there is a lot of dust, water vapor and dust can easily break through the sealing structure and invade the inside of the connector, leading to short circuit or poor contact of the connector, affecting the normal operation of the vehicle electrical system, and the prior art cannot realize long-term stable and efficient sealing protection; during vehicle driving, continuous vibration is generated, especially for the wire harness connector near the chassis and suspension, the traditional protection device lacks effective anti-vibration structure design, and long-term vibration can easily cause the connector to loosen and shift, and at the same time, the traditional protection device is mostly of fixed size structure, cannot adapt to wire harness connectors of various specifications in different vehicle models and different positions, needs to be designed and manufactured separately for different scenarios, increases the production cost and installation complexity, and reduces the universality and practicality of the device; the existing vehicle wire harness connector protection device can only play a passive physical protection role, cannot monitor key operating parameters such as ambient temperature and humidity, vibration intensity and connector contact resistance in real time. When the connector has potential faults such as oxidation of the contact point and sealing failure, it cannot send early warning signals in time, is prone to fault expansion, causes vehicle electrical system failure, and even causes safety accidents, lacks the ability of active early warning and fault intervention.

[0003] Therefore, it is necessary to design a protection device for the junction of vehicle wire harness connector to solve the above problems. UTILITY MODEL CONTENTS

[0004] The utility model aims at solving the problems of the traditional vehicle wire harness connector protection device, such as insufficient sealing performance, weak anti-vibration ability, poor installation adaptability and lack of state monitoring function, provides a protection device with efficient physical protection and real-time state monitoring, realizes stable protection, convenient installation and early fault warning of the wire harness connector through optimized structure design, and guarantees the long-term stable operation of the vehicle electrical system.

[0005] To achieve the above object, the utility model provides the following technical scheme:

[0006] A kind of protection device of vehicle wiring harness connector, core structure includes protective sleeve, end cap, fixed connection column, monitoring unit and inner guide sleeve, each component cooperates to realize the function of protection and monitoring;

[0007] The protective sleeve is the core bearing component of the device, and an accommodation space for accommodating the vehicle wiring harness connector is formed inside the protective sleeve. The accommodation space can accommodate wiring harness connectors of different specifications, providing a closed protective environment for the connectors. On the left and right sides of the protective sleeve in the axial direction, end caps are respectively assembled. The end caps can completely close both ends of the accommodation space, preventing moisture, dust and other impurities in the external environment from entering the interior of the accommodation space. The outer wall of the protective sleeve is also provided with a fixed connection column for fixing and installing the entire protection device at a designated position on the vehicle, ensuring that the device does not shift during vehicle operation. At the same time, the protective sleeve is integrated with a monitoring unit that can collect and analyze real-time operating state parameters of the wiring harness connector connection, allowing potential faults to be detected in a timely manner. In addition, the inner guide sleeve is installed inside the protective sleeve through a clamping method. The inner guide sleeve can guide the wiring harness to pass through the protection device in an orderly manner, preventing the wiring harness from being damaged by friction with the inner wall of the device.

[0008] Further, to achieve stable connection of the inner guide sleeve and the protective sleeve, an interference groove is formed on the inner wall of the protective sleeve accommodation space. Correspondingly, an elastic interference ring adapted to the interference groove is provided on the outer wall of the inner guide sleeve. The elastic interference ring has a certain elastic deformation capacity. When the inner guide sleeve is installed in the protective sleeve accommodation space, the elastic interference ring can precisely engage with the interference groove, thereby stably fixing the inner guide sleeve inside the protective sleeve and preventing the inner guide sleeve from shifting due to vehicle vibration. At the same time, a ball groove is formed around the inside of the inner guide sleeve, and a plurality of freely rolling balls are embedded and installed in the ball groove. When the wiring harness passes through the inner guide sleeve, the balls come into direct contact with the surface of the wiring harness. During the movement of the wiring harness, the balls roll, converting the sliding friction between the wiring harness and the inner wall of the inner guide sleeve into rolling friction, significantly reducing the wear on the surface of the wiring harness and protecting the integrity of the wiring harness insulation layer.

[0009] Furthermore, to enhance the sealing performance of the protection device, the connection between the end cap and the protective sleeve is designed as a stepped sealing part. The end of the protective sleeve is provided with a sealing groove that matches the stepped sealing part. The stepped sealing part and the sealing groove can form multiple sealing contact surfaces. At the same time, a sealing ring is installed between the two. The sealing ring can fill the tiny gap between the stepped sealing part and the sealing groove, effectively preventing external moisture and dust from entering the containment space from the connection gap between the end cap and the protective sleeve. In addition, the end cap is provided with a wire harness through hole for the wire harness to pass through. An elastic sealing sleeve is installed in the wire harness through hole. The inner wall of the elastic sealing sleeve is provided with an annular sealing lip. The annular sealing lip is elastic. When the wire harness passes through the elastic sealing sleeve, the annular sealing lip can tightly fit the outer wall of the wire harness, forming a special seal for the wire harness through hole, further enhancing the overall sealing and protection effect of the device and preventing impurities from entering from the gap between the wire harness and the through hole.

[0010] Furthermore, the fixed connecting posts are symmetrically arranged radially along the protective sleeve. This symmetrical layout ensures uniform stress distribution after installation, improving the installation stability of the device in vehicle vibration environments. The fixed connecting posts are provided with oblong mounting holes, the length of which is aligned with the axial direction of the protective sleeve. Compared to traditional circular mounting holes, oblong mounting holes provide a certain adjustment margin in the length direction. When there is a slight deviation in the vehicle installation position, the device can be fixed by adjusting the position of the bolts in the oblong mounting holes without re-drilling, reducing installation difficulty and improving the adaptability of the device to different vehicle models and installation scenarios.

[0011] Furthermore, the monitoring unit is the intelligent core of the device, consisting of three parts: sensor components, data processing unit, and early warning unit. These parts work together to achieve status monitoring and fault early warning functions.

[0012] The sensor assembly includes a temperature and humidity sensor, a vibration sensor, and a contact resistance sensor. The temperature and humidity sensor is embedded in the inner wall of the protective housing and can directly monitor the temperature and humidity parameters of the environment around the connector, and promptly detect harsh environments such as high temperature and high humidity. The vibration sensor is attached to the outer wall of the protective housing and can collect the vibration intensity and frequency of the device in real time during vehicle operation to determine whether the vibration exceeds the safe range. The contact resistance sensor abuts against the metal contacts of the connector through an elastic probe and can accurately monitor the resistance value of the connector contact point, reflecting the conduction status of the connector connection.

[0013] The data processing unit uses a micro MCU chip and is integrated on the monitoring unit. This module is electrically connected to the sensor components through wires. It can receive the raw data collected by each sensor in real time and analyze and process the data through a preset algorithm to determine whether the data exceeds the preset safety threshold.

[0014] The early warning unit consists of a buzzer and an LED indicator. It is also installed on the monitoring unit and is electrically connected to the data processing unit. When the data processing unit analyzes and finds that the data of a certain sensor exceeds the safety threshold, it immediately sends a control signal to the early warning unit, driving the buzzer to emit an audible alarm and the LED indicator to flash. This dual early warning method reminds staff to troubleshoot the fault in time and prevent the fault from escalating.

[0015] Compared with the prior art, the beneficial effects of this utility model are:

[0016] In this utility model, a protective device for the connection of a vehicle wiring harness connector achieves the following effects: 1. This device forms a multi-layer sealing structure by setting a stepped sealing part, a sealing groove, and a sealing ring at the connection between the end cover and the protective sleeve, and setting an elastic sealing sleeve with an annular sealing lip inside the wiring harness through hole of the end cover. The cooperation between the stepped sealing part and the sealing groove enhances the sealing performance of the connection between the end cover and the protective sleeve. The annular sealing lip can tightly fit the outer wall of the wiring harness, effectively preventing moisture and dust from entering. Compared with the traditional single sealing structure, the sealing effect is more durable and stable, avoiding short circuits or poor contact problems of the connector due to sealing failure, and ensuring the stable operation of the vehicle's electrical system; 2. On the one hand, the protective sleeve achieves stable installation through the fixed connecting post and the waist-shaped mounting hole. The waist-shaped mounting hole can adjust the installation position within a certain range to adapt to different installation scenarios, and the fixed connecting post is symmetrically arranged radially, improving the overall installation stability of the device and reducing the impact of vibration on the device; on the other hand, the inner guide sleeve is connected to the inner wall of the protective sleeve's accommodating space through an elastic interference ring. The interference fit of the slot ensures easy installation and a stable connection. The internal ball bearing design of the inner guide sleeve reduces friction between the wire harness and the inner wall of the device, preventing damage from vibration. Furthermore, the overall structure is compatible with various wire harness connectors, eliminating the need for custom designs, reducing production costs and installation complexity, and enhancing versatility and practicality. 3. The temperature and humidity sensor, vibration sensor, and contact resistance sensor in the monitoring unit can collect real-time data on the ambient temperature and humidity around the connector, the vibration intensity and frequency of the device, and the resistance value of the connector contact point. The data processing unit analyzes and processes the collected data. When the data exceeds a preset threshold, the alarm unit's buzzer sounds and the LED indicator flashes, promptly issuing a fault warning signal. Staff can promptly investigate and handle potential faults based on early warning information, preventing the fault from escalating and causing vehicle electrical system failures or safety accidents. This transforms traditional passive protection into active protection and early warning, improving vehicle operation safety and reliability. 4. The inner guide sleeve not only guides the vehicle wiring harness, ensuring its orderly arrangement and preventing tangling, but its internal balls also convert the sliding friction between the wiring harness and the inner wall of the inner guide sleeve into rolling friction, significantly reducing frictional damage during wiring harness installation and use, extending the service life of the wiring harness, and further ensuring the stability and safety of vehicle wiring harness connector connections. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall three-dimensional structure of this utility model;

[0018] Figure 2 This is a three-dimensional structural diagram of the inner conductor and protective sleeve of this utility model after disassembly;

[0019] Figure 3 This is a side view of the structure of this utility model;

[0020] Figure 4 This is a schematic diagram of the main structure of this utility model;

[0021] Figure 5 This is a connection block diagram of the monitoring unit of this utility model.

[0022] In the diagram: 1. Protective sleeve; 2. End cap; 3. Fixed connecting post; 4. Monitoring unit; 5. Inner guide sleeve; 6. Interference groove; 7. Elastic interference ring; 8. Ball groove; 9. Ball; 41. Sensor assembly; 411. Temperature and humidity sensor; 412. Vibration sensor; 413. Contact resistance sensor; 42. Data processing unit; 43. Early warning unit. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.

[0024] To facilitate understanding of this utility model, a more comprehensive description will be given below with reference to the accompanying drawings. Several embodiments of this utility model are provided. However, this utility model can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided so that the disclosure of this utility model will be more thorough and complete.

[0025] Example 1

[0026] Please see Figure 1 This embodiment provides a protective device for the connection of a vehicle wiring harness connector, including a protective sleeve 1. The protective sleeve 1 is injection molded from flame-retardant PA66 material and has a cylindrical structure with openings at both ends. The inside of the sleeve forms a receiving space for accommodating the vehicle wiring harness connector. The inner diameter of the receiving space is designed according to the specifications of commonly used vehicle wiring harness connectors. The wall thickness of the protective sleeve 1 is uniform, which ensures structural strength while reducing weight. The outer wall is reserved for mounting positions for installing and fixing the connecting post 3 and the monitoring unit 4.

[0027] There are two end caps 2, which correspond to the left and right sides of the protective sleeve 1 respectively. They are made of the same flame-retardant PA66 material as the protective sleeve 1. The outer diameter of the end cap 2 is the same as the outer diameter of the protective sleeve 1, and the inner diameter is adapted to the inner diameter of the accommodating space of the protective sleeve 1. After assembly, it can completely seal the two ends of the accommodating space to prevent external impurities from entering.

[0028] The fixed connecting post 3 is connected to the protective sleeve 1 by an integrated injection molding method. There are two of them, which are symmetrically distributed on the outer wall of the protective sleeve 1. The axis of the fixed connecting post 3 is consistent with the radial direction of the protective sleeve 1, and its end extends 5-8mm beyond the outer wall of the protective sleeve 1. It is used to connect and fix to the vehicle body or bracket.

[0029] The monitoring unit 4 is fixed to the mounting position on the outer wall of the protective sleeve 1 by screws. It has a rectangular box-shaped structure and integrates sensor assembly 41, data processing unit 42 and early warning unit 43 inside. It is covered with a waterproof coating to ensure normal operation in humid environments.

[0030] The inner guide sleeve 5 is made of wear-resistant polyethylene material and is cylindrical in shape. Its outer diameter is adapted to the inner diameter of the space to be accommodated in the protective sleeve body 1. It is installed inside the protective sleeve body 1 by a snap-fit ​​method. Its axis coincides with the axis of the protective sleeve body 1. Its inner wall is smooth and can guide the wire harness to pass through axially to avoid wire harness deviation.

[0031] In this embodiment, the vehicle wiring harness connector is placed into the receiving space of the protective sleeve 1, ensuring that the metal contacts of the connector face the preset monitoring position. The inner guide sleeve 5 is inserted into the receiving space from one end of the protective sleeve 1 and fixed by a snap-fit ​​structure (which will be further refined in subsequent embodiments), so that the inner guide sleeve 5 is located between the connector and the end cap 2. The two end caps 2 are respectively snapped onto the left and right sides of the axial direction of the protective sleeve 1, ensuring that the connecting surfaces of the end caps 2 and the protective sleeve 1 are in contact, thus sealing the receiving space. The entire device is connected to the designated installation position on the vehicle by the fixed connecting post 3. The fixing is completed by passing bolts through the mounting holes of the fixed connecting post 3. The wiring of the monitoring unit 4 is checked to ensure that it can monitor the status of the connector connection in real time.

[0032] Example 2

[0033] Please see Figure 2 Based on Embodiment 1, this embodiment further refines the fixing structure and guiding function of the inner guide sleeve 5:

[0034] An interference groove 6 is formed along the circumference of the inner wall of the receiving space of the protective sleeve 1. The cross-section of the interference groove 6 is trapezoidal, the groove depth is 2-3mm, the groove width is 3-4mm, and the position of the interference groove 6 is located in the middle of the receiving space, corresponding to the installation height of the inner guide sleeve 5.

[0035] On the outer wall of the inner guide sleeve 5, an elastic interference ring 7 is integrally formed along the circumferential direction. The elastic interference ring 7 is made of nitrile rubber material, which has good elasticity and wear resistance. Its cross-sectional shape is perfectly matched with the trapezoidal cross-section of the interference groove 6, and its thickness is 0.5-1mm greater than the groove depth of the interference groove 6.

[0036] During assembly, the inner guide sleeve 5 is aligned with the receiving space of the protective sleeve body 1, and an axial force is applied to cause the elastic interference ring 7 to undergo elastic deformation. When the elastic interference ring 7 reaches the position of the interference groove 6, the elastic deformation is restored, and the elastic interference ring 7 is fully embedded in the interference groove 6, so that the inner guide sleeve 5 and the protective sleeve body 1 are firmly engaged. Even if the vehicle vibrates violently, the inner guide sleeve 5 will not be axially displaced.

[0037] Example 3

[0038] Please see Figure 2 Based on embodiment 2, this embodiment further defines the ball groove 8 uniformly around the inside of the inner guide sleeve 5. The cross-section of the ball groove 8 is semi-circular, the diameter of which is adapted to the diameter of the ball 9, the length of the ball groove 8 is consistent with the length of the inner guide sleeve 5, and the groove opening faces the axis of the inner guide sleeve 5.

[0039] Each ball groove 8 is fitted with a freely rolling ball 9. The ball 9 is made of stainless steel and the surface is polished to reduce the coefficient of friction. The diameter of the ball 9 is 0.2-0.3mm larger than the diameter of the ball groove 8 to ensure that the ball 9 protrudes from the ball groove 8 and can contact the surface of the wire harness through which it passes.

[0040] When the wire harness passes through the inner guide sleeve 5, the surface of the wire harness comes into contact with the ball bearing 9. During the movement of the wire harness, the ball bearing 9 is driven to roll, which transforms the sliding friction between the wire harness and the inner wall of the inner guide sleeve 5 into rolling friction, greatly reducing the wear of the wire harness insulation layer. This is especially suitable for scenarios where the wire harness needs to move frequently and slightly (such as when the wire harness deforms slightly with the vehicle body during vehicle movement).

[0041] Example 4

[0042] Please see Figure 1 as well as Figure 3 Based on embodiment 1, this embodiment further defines the connection end of end cap 2 and protective sleeve 1 (i.e. the side of end cap 2 facing protective sleeve 1) as integrally formed with a stepped sealing part. The stepped sealing part is composed of 2-3 coaxial annular bosses. The diameter of each boss decreases sequentially, and the height is 2-3mm. The cross section of the boss is rectangular.

[0043] At the end of the protective sleeve 1 (i.e. the side of the protective sleeve 1 facing the end cap 2), a sealing groove adapted to the boss is opened corresponding to the shape of the stepped sealing part. The depth of the sealing groove is the same as the height of the boss, and the width is 0.2-0.3mm larger than the width of the boss.

[0044] A sealing ring is placed inside the sealing groove. The sealing ring is made of EPDM rubber and has good high temperature resistance and aging resistance. The cross-section of the sealing ring is circular and the diameter is 0.5-1mm larger than the depth of the sealing groove.

[0045] When assembling end cap 2, align the stepped sealing part of end cap 2 with the sealing groove of protective sleeve 1, apply pressure to make the stepped sealing part squeeze the sealing ring, the sealing ring undergoes elastic deformation, fills the gap between the sealing groove and the stepped sealing part, forming multiple seals, effectively preventing water vapor and dust from entering the receiving space from the connection gap between end cap 2 and protective sleeve 1.

[0046] Example 5

[0047] Please see Figure 1 as well as Figure 3 Based on embodiment 1, this embodiment further specifies that a wire harness through hole is opened at the center position of the end cap 2. The diameter of the wire harness through hole is 1-2 mm larger than the diameter of a commonly used wire harness to ensure that the wire harness can pass through smoothly.

[0048] An elastic sealing sleeve is embedded in the wire harness through hole. The elastic sealing sleeve is made of fluororubber material, which has excellent oil resistance and chemical corrosion resistance. The outer diameter of the elastic sealing sleeve is interference-fitted with the inner diameter of the wire harness through hole to ensure that the elastic sealing sleeve is fixed in the wire harness through hole and does not fall off.

[0049] On the inner wall of the elastic sealing sleeve, 3-4 annular sealing lips are evenly arranged along the axial direction. The cross-section of the annular sealing lip is triangular, with a height of 1-1.5mm, and it has good elasticity.

[0050] When the wire harness passes through the elastic sealing sleeve, the annular sealing lip fits tightly against the outer wall of the wire harness under its own elasticity. Even if there are slight differences in the diameter of the wire harness, the annular sealing lip can adapt through deformation to form multiple radial seals, preventing impurities from entering the receiving space from the gap between the wire harness and the wire harness through hole.

[0051] Example 6

[0052] Please see Figure 1 , Figure 4 as well as Figure 5 Based on Example 1, this embodiment optimizes the structure of the fixed connection column 3 and the function of the monitoring unit 4:

[0053] Two fixed connecting columns 3 are arranged symmetrically along the radial direction of the protective sleeve 1. The axes of the two fixed connecting columns 3 are on the same straight line and perpendicular to the axis of the protective sleeve 1 to ensure that the device is balanced under force after installation.

[0054] At the end of each fixed connecting column 3, a waist-shaped mounting hole is opened along the axial direction of the protective sleeve 1, with the length direction consistent with the axial direction of the protective sleeve 1.

[0055] During installation, the bolts pass through the waist-shaped mounting holes and connect to the vehicle body or bracket. When there is a deviation of ±3mm in the vehicle installation position, there is no need to re-drill holes. Simply adjust the position of the bolts in the waist-shaped mounting holes to complete the alignment, which greatly reduces the installation difficulty and adapts to the installation requirements of different vehicle models, improving the versatility of the device.

[0056] Example 7

[0057] Please see Figure 5 Based on Embodiment 1, this embodiment further defines the sensor assembly 41 as including a temperature and humidity sensor 411, a vibration sensor 412, and a contact resistance sensor 413.

[0058] The temperature and humidity sensor 411 is mounted on a patch and embedded in the inner wall of the housing 1, with a distance of 5-10mm from the connector. It can monitor the temperature (measurement range -40℃~125℃) and humidity (measurement range 0%RH~100%RH) in the housing in real time, with a data accuracy of ±0.5℃ and ±2%RH.

[0059] The vibration sensor 412 is fixed by adhesive and installed on the outer wall of the protective sleeve 1, near the fixed connecting post 3. It can monitor the vibration intensity (measurement range 0~500m / s²) and frequency (measurement range 1~1000Hz) of the device during vehicle operation and provide real-time feedback on the impact of vibration on the device.

[0060] The contact resistance sensor 413 has an elastic probe at its end. The elastic probe is made of gold-plated copper alloy material, which has good conductivity and wear resistance. The elastic probe passes through the inner wall of the protective sleeve 1 and extends into the receiving space to abut against the metal contact of the connector. The contact pressure is maintained at 1-2N, which can monitor the resistance value of the connector contact point (measurement range 0.1mΩ~10Ω) and reflect the conduction status of the connector.

[0061] The data processing unit 42 uses an STM32 series micro MCU chip, which is integrated on the internal circuit board of the monitoring unit 4. It is electrically connected to the temperature and humidity sensor 411, vibration sensor 412, and contact resistance sensor 413 via wires. The data processing unit 42 has built-in preset thresholds (such as temperature > 85℃, humidity > 80%RH, vibration intensity > 100m / s², contact resistance > 50mΩ), which can receive the data collected by each sensor in real time and compare and analyze it with the preset thresholds to determine whether the connector connection is in a normal state.

[0062] The early warning unit 43 includes a buzzer and an LED indicator, both of which are mounted on the surface of the monitoring unit 4 and electrically connected to the data processing unit 42 via wires. When the data processing unit 42 detects that the data of a certain sensor exceeds a preset threshold, it immediately sends a control signal to the early warning unit 43, driving the buzzer to emit a continuous alarm sound of 2kHz, and at the same time controlling the LED indicator (red) to flash at a frequency of 1 time / second. This dual early warning method ensures that staff can detect the fault in time and prevent the fault from escalating.

[0063] The working process of this utility model is as follows: When using the protective device for the connection of the vehicle wiring harness connector, firstly, place the vehicle wiring harness connector into the receiving space of the protective sleeve 1, aligning the metal contacts of the connector with the elastic probe position of the contact resistance sensor 413. Take the inner guide sleeve 5, aligning the elastic interference ring 7 on its outer wall with the interference groove 6 on the inner wall of the receiving space of the protective sleeve 1. Apply axial force to deform the elastic interference ring 7 and embed it into the interference groove 6, completing the locking and fixing of the inner guide sleeve 5, ensuring that the axis of the inner guide sleeve 5 coincides with the axis of the protective sleeve 1, preparing for the guidance of the wiring harness. Then, place sealing rings in the sealing grooves at both ends of the protective sleeve 1, take two end caps 2, align the stepped sealing part of the end cap 2 with the sealing groove of the protective sleeve 1, fasten the end caps 2 and apply pressure, so that the stepped sealing part squeezes the sealing ring to form a multiple seal, sealing both ends of the receiving space. Pass the wiring harness through the wiring harness through hole of the end cap 2, so that the outer wall of the wiring harness is flush with the sealing groove. The annular sealing lip of the elastic sealing sleeve inside the through hole fits tightly, and the radial seal between the wire harness and the through hole is achieved through the elastic deformation of the annular sealing lip to prevent impurities from entering. Using the fixed connecting post 3 on the outer wall of the protective sleeve 1, the device is aligned with the vehicle installation position. The bolt is passed through the waist-shaped mounting hole of the fixed connecting post 3. The position of the bolt in the waist-shaped mounting hole (along the axial direction of the protective sleeve 1) is adjusted according to the actual installation deviation. After confirming the position, the bolt is tightened to complete the fixation of the device to the vehicle. After ensuring the force balance after installation, the wiring status of the monitoring unit 4 is checked to ensure that the electrical connection between the sensor assembly 41 and the data processing unit 42 and the early warning unit 43 (buzzer, LED indicator) is normal. The monitoring unit 4 is started, and the preset thresholds (such as temperature > 85℃, humidity > 80%RH, vibration intensity > 100m / s², contact resistance > 50mΩ) by the data processing unit 42 are completed and ready to enter the monitoring state.

[0064] Temperature and humidity sensor 411 (embedded in the inner wall of the protective sleeve 1) continuously collects temperature and humidity data of the environment around the connector, with an accuracy of ±0.5℃ and ±2%RH. Vibration sensor 412 (attached to the outer wall of the protective sleeve 1) monitors the vibration intensity (0~500m / s²) and frequency (1~1000Hz) of the device in real time during vehicle operation, providing feedback on the impact of vibration on the device. Contact resistance sensor 413 (contacts the connector's metal contact point via an elastic probe with a contact pressure of 1-2N) monitors the resistance value (0.1mΩ~10Ω) of the connector contact point, reflecting the connector's conduction status. Sensor assembly 41 transmits the collected raw data to data processing unit 42 (STM32 series micro MCU chip) in real time. Data processing unit 42 analyzes the data and compares the real-time data with preset thresholds: if all data are within the threshold range, the connector connection is considered normal, and the device continues monitoring; if any data exceeds the threshold (e.g., excessively high temperature or excessively high contact resistance), an early warning mechanism is immediately triggered.

[0065] When the data processing unit 42 determines that the data exceeds the threshold, it sends a control signal to the early warning unit 43, driving the buzzer to emit a continuous 2kHz alarm sound. At the same time, it controls the LED indicator (red) to flash at a frequency of 1 time / second, thus alerting the staff to the fault through a dual warning of sound and light. The staff locates the device position based on the warning signal and determines the fault type based on the feedback from the monitoring unit 4 (e.g., abnormal temperature and humidity correspond to seal failure, abnormal contact resistance corresponds to loose connector). The staff then takes appropriate action based on the fault type: if it is a seal failure, check the sealing structure or elastic sealing sleeve of the end cover 2 and replace the damaged parts; if it is a loose connector, open the end cover 2 and re-fix the connector to ensure that the contact resistance sensor 413 and the metal contact of the connector are in normal contact. After the processing is completed, the monitoring unit 4 is restarted, and once the data is confirmed to be normal, the warning signal stops, and the device returns to normal monitoring status.

[0066] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A protective device for the connection of a vehicle wiring harness connector, characterized in that: The device includes a protective sleeve (1), which has a receiving space for accommodating vehicle wiring harness connectors. The protective sleeve (1) has end caps (2) on its left and right axial sides. The end caps (2) are used to close the two ends of the receiving space. The protective sleeve (1) is also provided with a fixed connecting post (3) for fixing the protective sleeve (1). The protective sleeve (1) is provided with a monitoring unit (4) for monitoring the status of the connection of the vehicle wiring harness connector. The protective sleeve (1) is internally fitted with an inner guide sleeve (5) for guiding the vehicle wiring harness.

2. The protective device for the connection of a vehicle wiring harness connector according to claim 1, characterized in that: The inner wall of the accommodating space of the protective sleeve (1) is provided with an interference groove (6), and the outer wall of the inner guide sleeve (5) is provided with an elastic interference ring (7) adapted to the interference groove (6). The elastic interference ring (7) is engaged with the interference groove (6) to fix the inner guide sleeve (5).

3. The protective device for the connection of a vehicle wiring harness connector according to claim 1, characterized in that: The end cap (2) and the protective sleeve (1) are connected by a stepped sealing part. The end of the protective sleeve (1) is provided with a sealing groove that is adapted to the stepped sealing part. A sealing ring is provided between the stepped sealing part and the sealing groove.

4. The protective device for the connection of a vehicle wiring harness connector according to claim 1, characterized in that: The fixed connecting column (3) is arranged symmetrically along the radial direction of the protective sleeve (1). The fixed connecting column (3) is provided with a waist-shaped mounting hole. The length direction of the waist-shaped mounting hole is consistent with the axial direction of the protective sleeve (1).

5. The protective device for the connection of a vehicle wiring harness connector according to claim 1, characterized in that: The end cap (2) is provided with a wire harness through hole, and an elastic sealing sleeve is provided inside the wire harness through hole. The inner wall of the elastic sealing sleeve is provided with an annular sealing lip, and the annular sealing lip is tightly fitted to the outer wall of the wire harness.

6. The protective device for the connection of a vehicle wiring harness connector according to claim 1, characterized in that: The inner guide sleeve (5) has a ball groove (8) inside, and multiple rolling balls (9) are embedded in the ball groove (8) so that the balls (9) contact the wire harness surface and avoid friction between the inner wall of the protective sleeve (1) and the wire harness surface.

7. The protective device for the connection of a vehicle wiring harness connector according to claim 1, characterized in that: The monitoring unit (4) includes a sensor assembly (41), a data processing unit (42), and an early warning unit (43). The sensor assembly (41) includes a temperature and humidity sensor (411), a vibration sensor (412), and a contact resistance sensor (413). The temperature and humidity sensor (411) is embedded in the inner wall of the connector cavity and is used to monitor the temperature and humidity of the environment around the connector. The vibration sensor (412) is attached to the outer wall of the protective sleeve (1) and is used to monitor the vibration intensity and frequency of the device during vehicle operation. The contact resistance sensor (413) abuts against the metal contact of the connector through an elastic probe and is used to monitor the resistance value of the connector contact point. The data processing unit (42) uses a micro MCU chip and is set on the monitoring unit (4). The data processing unit (42) is electrically connected to the sensor assembly (41) and is used to receive and analyze the data collected by the sensor. The warning unit (43) includes a buzzer and an LED indicator, which are installed on the monitoring unit (4). The warning unit (43) is electrically connected to the data processing unit (42). When the data collected by the sensor exceeds the preset threshold, the data processing unit (42) drives the buzzer to sound and the LED indicator to flash, thereby realizing fault warning.

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