TESTING TOOL AND PROCEDURE

Description

Technical area

[0001] The invention relates to a testing tool and method for testing a connector position lock of a connector. State of the art

[0002] EP 2 831 959 B1 discloses an electrical connector for a wiring harness with a connector position assurance (CPA) element that is slidably arranged on an outer side of a connector housing. Once the connector is fully connected to a corresponding mating part, the CPA element can be moved from a non-locked position to a locked position. CPA elements thus offer a visual inspection option to verify whether a connector and its corresponding mating part are fully mated. Furthermore, the CPA element provides a mechanical safeguard to prevent accidental separation of the connector and mating part.

[0003] In an assembly line, for example, for vehicle production, every connector must be reliably tested for correct assembly and locking. Verifying a correct connector connection can be done using a push / pull test, which, according to established Process Failure Modes and Effects Analysis (PFMEA) criteria, must be performed by a second worker on the assembly line. Alternatively, a visual inspection can be performed automatically using a camera and connected image processing system, for example, by optically determining whether a CPA element is in its locked position or not.

[0004] One problem is that the corresponding plug connection must be quickly and easily accessible for inspection. Not all production processes have sufficient installation space available for a second worker to check the correct fit of a plug connection using a push / pull test. Even with camera-based testing, an assembled or plugged connection consisting of a connector and its counterpart is not always sufficiently visible for visual inspection. Furthermore, while a camera generally delivers a clear and easily documented result, false negative results can also occur due to factors such as reflections, different lighting conditions (glare, shadows), dirty components, etc.

[0005] EP 3 806 247 A1 discloses a method for checking a connection position of a connector, wherein a machine-readable visual identifier can be scanned by a sensor only if the connection position is correct.

[0006] From US 9 491 557 B2 a system and method for a secured plug connection is known, wherein the correct assembly and locking of the plug connection is acoustically detected during assembly by means of a microphone.

[0007] The document DE 102016000981 A1 discloses a similar system for checking the correct mating state of a connector. Brief description of the invention

[0008] Against this background, the object of the invention is to provide an alternative possibility to reliably check the correct assembly and locking of a connector with a position securing element.

[0009] Accordingly, a testing tool according to the main claim and a method according to the secondary claim are proposed. Further embodiments are the subject of the respective dependent claims.

[0010] According to a first aspect of the invention, the object is achieved by a testing tool for testing a connector position securing device of a connector. The testing tool comprises a housing body, wherein a recess is arranged on one housing side of the housing body for at least partially immersing or inserting a connector housing of a connector to be tested. On a lower side of the recess, at least one first contact surface is formed, against which a corresponding surface section of an upper connector housing side of a connector to be tested can be brought into contact, provided that a position securing element on the upper connector housing side of the connector to be tested is in a locking position.Furthermore, a second contact surface is arranged on the lower side of the recess, against which a position-securing element of a connector to be tested, arranged on an upper side of the connector housing, can be brought into contact, provided the position-securing element is not in a locking position. The first contact surfaces and the second contact surface are arranged relative to one another in such a way that a corresponding surface section of an upper side of the connector housing of a connector to be tested cannot be brought into contact with the first contact surfaces, while a position-securing element of the connector to be tested that is not in a locking position bears against the second contact surface.

[0011] One idea behind the present invention is to provide a testing tool that forms a negative mold of a connector to be tested. The testing tool only fits correctly on the connector to be tested if the connector is correctly positioned on the counterpart and if the position-locking element is in its locked position. According to a further development of the testing tool, a contact sensor can be arranged on the at least one first contact surface.

[0012] Thus, by placing the test tool on a correctly mounted connector with a locked position securing element, an electrical signal can be generated that can be evaluated by an assembly line control system.

[0013] According to a further development, the system sensor can comprise a microswitch.

[0014] The microswitch can be arranged within the housing body on the lower side of the recess. A switching tongue of the microswitch can protrude into the recess through a hole in the lower side in the area of ​​the first contact surface and serve as a sensing element for detecting an adjacent corresponding surface section of a connector under test.

[0015] According to a further development of the testing tool, two first contact surfaces, each with a contact sensor, can be formed on the lower side of the recess.

[0016] The two first contact surfaces can preferably be positioned relative to each other on the lower side of the recess in such a way that they cannot be touched simultaneously by a worker's finger. This ensures fail-safe handling of the testing tool, as simultaneous false triggering of both contact sensors is at least made more difficult.

[0017] According to a further development of the testing tool, a contour of a lateral side of the recess can be adapted to a lateral contour of a plug housing of a connector to be tested in such a way that the first contact surface is aligned substantially parallel to a respective corresponding surface section of an upper plug housing side when the plug housing is immersed in the recess.

[0018] This ensures that a connector to be tested cannot become tilted when immersed in the recess in such a way that a system sensor could be incorrectly triggered.

[0019] According to a second aspect of the invention, the object is achieved by a method for testing a connector position lock of a connector using a test tool as described above. The test tool is placed on the connector after a plug connection has been established between the connector and a counterpart. At least one first contact surface on a lower side of a recess in a housing body of the test tool is brought into contact with a corresponding surface portion of an upper connector housing side of the connector when a position lock element on the upper connector housing side of the connector is in a locked position.A second contact surface on the lower side of the recess is brought into contact with a position-locking element of the connector arranged on an upper side of the connector housing when the position-locking element is not in a locking position. The corresponding surface section of the connector cannot be brought into contact with the first contact surfaces if a position-locking element of the connector that is not in a locking position abuts the second contact surface.

[0020] According to a further development of the method, a signal can be generated by means of a contact sensor arranged on the at least one first contact surface as soon as a contact of the at least one first contact surface on a corresponding surface section of the upper plug housing side of the plug connector is detected.

[0021] The generated signal can be sent to an assembly line control system and evaluated by it. This allows subsequent assembly steps on a production line to be authorized by the assembly line control system once correct assembly and locking of the connector with a corresponding counterpart has been signaled. Short description of the drawing figures

[0022] Further features and details emerge from the following description, in which at least one exemplary embodiment is described in detail—possibly with reference to the drawing. Described and / or illustrated features constitute the subject matter, either individually or in any meaningful combination, possibly independently of the claims, and may, in particular, also be the subject of one or more separate applications. Identical, similar, and / or functionally identical parts are provided with the same reference numerals. Here, the following are shown: Figure 1 shows a connector with a position securing element according to the prior art; Figure 2 shows a perspective view of a testing tool according to the invention; Figure 3 shows a top view of the testing tool according to the invention; Figure 4 shows a sectional view through the testing tool; Figure 5 shows a sectional view through the test tool and through a connector to be tested with an unlocked CPA element; Figure 6 shows a cross-sectional view through the test tool and through a connector under test with a properly locked CPA element. Description of the execution types

[0023] The Figure 1shows two representations of a connector 2 with a position assurance element (CPA element) 23. The connector 2 has a connector housing 20 with an upper connector housing side 22. The CPA element 23 is slidably arranged on the upper connector housing side 22. As soon as the connector 2 is connected to a corresponding counterpart, an internal mechanism allows the CPA element 23 to be moved from a non-locked position to a locked position. Figure 1a The connector 2 is shown with a CPA element 23 in a non-locked position. Figure 1b The connector 2 shown, whose CPA element 23 is in the locking position, is mechanically protected against accidental disconnection from a Figure 1b secured by a counterpart not shown. The CPA element 23 is guided in the connector housing 20 so as to be movable parallel to a plugging direction of the connector 2.

[0024] On the upper side 22 of the connector housing, two surface sections 21 are arranged, which extend laterally next to the CPA element 23 in the direction of displacement.

[0025] In the Figure 2 A perspective view of a test tool 1 according to the invention for testing a connector position lock of a connector 2 is shown. The test tool 1 has a housing body 10, with a recess 12 formed on one side 11 of the housing. The recess 12 is shaped such that a geometric negative form of a connector 2 to be tested is formed, at least in sections.

[0026] The test tool 1 can be placed on the connector 2 to check for a correct plug connection, so that the connector housing 20 can be immersed with its upper connector housing side 22 first into the recess 12 of the test tool 1.

[0027] At least one first contact surface 14 can be seen on a lower side 13 of the recess 12, against which a corresponding surface section 21 on the upper plug housing side 22 of a plug connector 2 to be tested can be brought into contact.

[0028] Within the first contact surface 14, a contact sensor 16 is arranged, with which an adjacent corresponding surface section 21 of a connector 2 to be tested can be detected.

[0029] Furthermore, a second contact surface 15 is provided on the lower side 13 of the recess 12, which is arranged above the at least one first contact surface 14 with respect to an immersion direction z.

[0030] As from the Figure 3 with a top view of the test tool 1, the lower side 13 of the recess 12 has a further first contact surface 14, which in the perspective view of the Figure 2is shown largely hidden. A further contact sensor 16 is arranged in the further first contact surface 14. The number of contact sensors 16 provided in a test tool 1 can be adapted to the design of a respective connector 2 to be tested. However, it is advantageous to provide at least two first contact surfaces 14, each with a contact sensor 16, in the recess 12 of the test tool 1. By suitably arranging the two first contact surfaces 14 with the associated contact sensor 16, fail-safe handling of the test tool 1 can be achieved. In conjunction with the geometry of the test tool 1, it can be prevented that both contact sensors 16 can be triggered, for example by a worker's finger.

[0031] In the Figure 4shows a sectional view through the testing tool 1. The contact sensors 16 can, for example, each comprise a microswitch 17 with a switching tongue 18, wherein the switching tongue 18 is guided through the housing body 10 and projects into the recess 12 on the lower side 13. The first contact surfaces 14 and the second contact surface 15 are arranged spaced apart horizontally, ie in the immersion direction z of the recess 12.

[0032] After a plug connection to be tested has been established by inserting a connector 2 into a corresponding counterpart, the test tool 1 can be used according to the sectional views in the Figures 5 and 6 , are placed on the connector 2. The connector housing 20 is consequently immersed with its upper connector housing side 22 at the front in the immersion direction z into the recess 12 in the housing body 10 of the test tool 1.

[0033] The lateral sides 19 of the recess 12 in the housing body 10 are adapted to the lateral contours of a connector housing 20 to be tested in such a way that the upper connector housing side 22 can be guided substantially parallel to the lower side 13 of the recess 13 when immersed.

[0034] In the Figure 5 shows a connector 2 that is not properly locked during a test procedure. The CPA element 23, which is not in its locked position, rests on the second contact surface 15 after the connector housing 20 has been inserted into the recess 12. The first contact surfaces 14 therefore do not contact the corresponding surface sections 21 on the upper side 22 of the connector housing. Since the position lock is not properly locked, the contact sensors 16 do not detect a contacting connector 2.

[0035] The Figure 6shows a connector 2 with a properly locked position lock, after the connector 2 has been connected to a corresponding counterpart. The CPA element 23 is therefore in its locking position. Thus, the first contact surfaces 14 in the recess 12 and the corresponding surface sections 21 of the upper connector housing side 22 of a connector 2 to be tested have been brought into contact. The contact sensors 16 thus detect an adjacent connector 2 whose CPA element is in a locking position. Since a CPA element can only be activated when the connector connection is properly mated, the contact sensors 16 can reliably detect correct assembly and locking.

[0036] When the test tool 1 is placed on the connector 2, the system sensors 16 embedded in the test tool 1 generate an analyzable signal that can be sent to an assembly line control system. A received signal can be used to authorize subsequent assembly steps on a production line.

[0037] Although the subject matter has been illustrated and explained in detail by means of exemplary embodiments, the invention is not limited by the disclosed examples, and other variations may be derived therefrom by those skilled in the art. It is therefore clear that a multitude of possible variations exist. It is also clear that the exemplary embodiments mentioned are merely examples and should not be construed as limiting the scope, possible applications, or configuration of the invention in any way.Rather, the preceding description and the description of the figures enable the person skilled in the art to implement the exemplary embodiments in concrete terms, whereby the person skilled in the art, with knowledge of the disclosed inventive concept, can make various changes, for example with regard to the function or the arrangement of individual elements mentioned in an exemplary embodiment, without departing from the scope of protection defined by the claims. List of reference symbols

[0038] 1Test tool 10Housing body 11Housing side 12Recess 13Lower side 14First contact surface 15Second contact surface 16Contact sensor 17Microswitch 18Switching tongue 19Side side 2Connector 20Connector housing 21Surface section 22Upper connector housing side 23Position securing element

Claims

1. Test tool for testing a plug connector position securing of a plug connector (2) comprising a housing body (10), wherein on a housing side (11) of the housing body (10) a recess (12) for at least partially immersing a plug housing (20) a plug connector to be tested (2) is arranged, wherein on a lower side (13) of the recess (12) at least one first contact surface (14) is formed, on which a corresponding surface section (21) an upper plug housing side (22) a plug connector to be tested (2) can be brought into contact, if a position securing element (23) on the upper plug housing side (22) of the plug connector to be tested The invention relates to a locking position, wherein a second contact surface (15) is arranged on the lower side (13) of the recess (12), on which a position securing element (23) of a plug connector (2) to be tested, which is arranged on an upper plug housing side (22), can be brought into contact if the position securing element (23) is not in a locking position, and wherein the first contact surfaces (14) and the second contact surface (15) are arranged relative to one another in such a way that a corresponding surface section (21) of an upper plug housing side (22) of a plug connector (2) to be tested cannot be brought into contact with the first contact surfaces (14), while a position securing element (23) that is not in a locking position The plug connector (2) rests against the second contact surface (15).

2. Test tool according to the preceding claim 2, wherein a contact sensor (16) is arranged on the at least one first contact surface (14).

3. Test tool according to claim 2, wherein the contact sensor (16) comprises a microswitch (17).

4. Test tool according to one of the two preceding claims 2 or 3, wherein at least two first contact surfaces (14) are formed with a respective contact sensor (16) on the lower side (13) of the depression (12).

5. Testing tool according to one of the preceding claims, wherein a contour of a lateral side (19) of the recess (12) is matched to a lateral contour of a plug housing (20) of a plug connector (2) to be tested in such a way that the first contact surface (14) is orientated substantially parallel to a respective corresponding surface section (21) of an upper plug housing side (22) when the plug housing (20) is immersed in the recess (12).

6. Method of testing a connector position lock of a connector (2) with a testing tool (1) according to any one of the preceding claims, wherein the testing tool (1) is placed on the connector (2) after a plug connection between the connector (2) and a counterpart has been made, wherein at least a first abutment surface (14) on a lower side (13) of a recess (12) in a housing body (10) of the testing tool (1) with a corresponding surface portion (21) of an upper connector housing side (22) of the connector (2) is brought into abutment when a position lock element (23) on the upper connector housing side (22) of the connector (2) is in a locked position, and wherein a second abutment surface is (15) on the lower side (13) of the recess (12) with a on an upper plug housing side (22) position securing element arranged (23) of the plug connector (2) when the position securing element (23) is not in a locking position, and wherein the corresponding surface section (21) of the plug connector (2) with the first contact surfaces (14) cannot be brought into contact when a not in a locking position securing element (23) of the plug connector (2) on the second contact surface (15) rests.

7. Method according to the preceding claim 6, wherein a signal is generated by means of an abutment sensor (16) arranged on the at least one first abutment surface (14) as soon as an abutment of the at least one first abutment surface (14) on a corresponding surface section (21) of the upper plug housing side (22) of the plug connector (2) is detected.