Connector health monitoring device

Abstract

A connector health monitoring device is needed that provides a reliable method for evaluating connector health. [Solution] The connector health monitoring device 100 for evaluating the health of an electrical connector includes a device housing 140 including a body that forms a cavity 150. The device housing has a mating end 112 configured to mate with an electrical connector. The connector health monitoring device includes a control element 160 received in the cavity. The control element includes a processor 165 for performing health evaluation of the electrical connector. The connector health monitoring device includes an inspection probe 110 held by the device housing. The inspection probe includes a mating interface for mating with inspectable contacts of the electrical connector. The inspection probe is positioned at the mating end for mating with inspectable contacts and is operably coupled to the control element.

Description

TECHNICAL FIELD

[0001] This application claims priority to U.S. Application No. 63 / 783,548 filed on April 4, 2025, the subject matter of which is hereby incorporated in its entirety into the present specification by reference.

[0002] The subject matter of the present specification relates to monitoring of electrical connector health. BACKGROUND ART

[0003] Electrical connectors experience wear and damage over time. For example, electrical connectors that undergo many mating and unmating cycles and / or electrical connectors operating in harsh environments experience wear and damage over time. Additionally, the presence of foreign matter or debris at a separable connector interface is a problem that may lead to damage to electrical connector components. Some known electrical connectors that have such issues include charging connectors used for charging. For example, the transition from internal combustion engine (ICE) vehicles to electric vehicles (EVs) presents significant challenges, particularly in ensuring safe charging at charging interfaces. Such interfaces where a vehicle connects to a charging station are an example of high-voltage interfaces that are susceptible to damage or degradation in the field as they are exposed to varying degrees of environmental exposure. Charging components are designed to be robust against handling of charging plugs of varying quality and condition. Solutions need to be developed to detect the health of the connection system and enable predictive maintenance. One of the main indicators of a connection failure is increased heat loss, which reduces overall charging efficiency. Reduced charging efficiency leads to increased charging power or charging duration. The increased costs due to such connection failures are passed on to the vehicle owner, resulting in a worse user experience for the end user. In some cases, connection failures can cause irreversible damage to the vehicle inlet, requiring maintenance or replacement. All of the above factors reiterate the growing need to detect and enable regular maintenance of charging plugs and detachable interfaces used in environments susceptible to damage from exposure to contaminants. Other types of connectors besides charging connectors also degrade and require maintenance. [Overview of the project] [Problems that the invention aims to solve]

[0004] A connector health monitoring device is needed that provides a reliable method for evaluating connector health in separable connector interfaces. [Means for solving the problem]

[0005] In one embodiment, a connector health monitoring device is provided for health assessment testing of electrical connectors. The connector health monitoring device includes a device housing including a body that forms a cavity. The device housing has a mating end configured to mate with an electrical connector. The connector health monitoring device includes a control element received in the cavity. The control element includes a processor for performing health assessment of the electrical connector. The connector health monitoring device includes an inspection probe held by the device housing. The inspection probe includes a mating interface for mating with inspectable contacts of the electrical connector. The inspection probe is positioned at the mating end for mating with inspectable contacts. The inspection device is operably coupled to the control element.

[0006] Please refer to the attached drawing for an example explanation of the drawing. [Brief explanation of the drawing]

[0007] [Figure 1] This figure shows a connector health monitoring device according to an exemplary embodiment. [Figure 2] This is a front view of a connector health monitoring device according to an exemplary embodiment. [Figure 3] This is a rear view of a connector health monitoring device according to an exemplary embodiment. [Figure 4] This is an exploded view of a connector health monitoring device according to an exemplary embodiment. [Figure 5] This is a front perspective view of a connector health monitoring device according to an exemplary embodiment. [Figure 6] This is a rear perspective view of a connector health monitoring device according to an exemplary embodiment. [Figure 7] This is a front perspective view of a connector health monitoring device according to an exemplary embodiment. [Figure 8] Figure 7 shows a rear perspective view of the connector health monitoring device according to an exemplary embodiment. [Figure 9] This figure shows a charge health monitoring system according to an exemplary embodiment. [Modes for carrying out the invention]

[0008] Figure 1 shows a connector health monitoring device 100 according to an exemplary embodiment. The connector health monitoring device 100 is used to evaluate the health of the mating interface of one or more electrical connectors 10. For example, the connector health monitoring device 100 may evaluate the health of a separable connector interface 12 of an electrical connector against foreign object debris (FOD) 14 and / or wear of the contacts or terminals of the electrical connector and / or the operational condition of the contacts or terminals of the electrical connector. In the exemplary embodiment, the electrical connectors 10 in the separable connector interface 12 include a first electrical connector 16 and a second electrical connector 18. The connector health monitoring device 100 may be used to inspect the interfaces of the first electrical connector 16 and / or the second electrical connector 18. In an exemplary embodiment, the connector health monitoring device 100 is used to inspect the electrical terminals or contacts 17 of the first electrical connector 16 and / or the electrical terminals or contacts 19 of the second electrical connector 18.

[0009] In an exemplary embodiment, the connector health monitoring device 100 includes one or more test probes 110 configured to mate with testable contacts of an electrical connector 10 in a separable connector interface 12. The test probes 110 may be plugged into the interfaces of a first electrical connector 16 and / or a second electrical connector 18. For example, the test probes 110 may mate with electrical terminals 17 of the first electrical connector 16 and / or electrical terminal 19 of the second electrical connector 18 to test electrical terminals 17, 19.

[0010] In an exemplary embodiment, the connector health monitoring device 100 includes an inspection probe 110 associated with an inspection probe 110. The inspection probe 110 is used to measure one or more health assessment characteristics of the inspectable contacts and / or electrical connector 10 in a separable connector interface 12. For example, health assessment characteristics may include mating force, electrical characteristics, contact resistance, contact wear, emissivity, contact size, contact shape, presence or absence of FOD, etc. Optionally, multiple test probes 110 may be provided to test different integrity characteristics and / or different electrical terminals or regions of the separable connector interface 12. In an exemplary embodiment, the test apparatus is configured for multi-parameter integrity analysis of the separable connector interface 12.

[0011] Figure 2 is a front view of the connector health monitoring device 100 according to an exemplary embodiment. Figure 3 is a rear view of the connector health monitoring device 100 according to an exemplary embodiment. The connector health monitoring device 100 includes a mating interface 102 configured to mate with an electrical connector 10 during inspection operation. The mating interface 102 is sized and shaped to interface with the electrical connector 10. In various embodiments, the mating interface 102 may have a standard interface for mating with the electrical connector 10. For example, the mating interface 102 may have a standard power charging interface, such as for electric vehicles. However, the connector health monitoring device 100 is not limited to inspecting the power charging interface of an electric vehicle. In various embodiments, the mating interface 102 may mimic the mating interface of an electric vehicle's charging inlet, so that the connector health monitoring device mimics the mating interface of an electric vehicle's charging inlet to inspect the charging plug of a charging station. For example, the mating interface 102 may be a CCS1 charging interface, a NACS charging interface, or a standard charging interface for another type of electric vehicle.

[0012] The connector health monitoring device 100 includes a device housing 140 that holds one or more of the test probes 110. The device housing 140 holds a control element 160 operably coupled to the test probe 110. The control element 160 includes one or more processors for performing a health assessment of the electrical connector 10. In an exemplary embodiment, the connector health monitoring device 100 may also include one or more indicators 170 operably coupled to the control element 160. The indicators 170 may provide the operator with a visual, auditory, or other type of indicator indicating the connector health of the electrical connector 10 during the test operation. For example, the indicator 170 may include LED lights that provide visual indicators to the operator, such as green and red lights that indicate good or bad conditions, respectively. In alternative embodiments, other types of indicators may be used.

[0013] The device housing 140 includes a body 142 extending between the front 144 and rear 146 of the device housing 140. In the illustrated embodiment, the indicator 170 is located at the rear 146. In alternative embodiments, other locations are possible. In exemplary embodiments, the body 142 may be manufactured from a dielectric material, such as a plastic material. For example, the body 142 may be a molded part, such as an injection-molded part. The body 142 may be a multi-part body formed by the coupling of multiple parts to each other to form the device housing 140. The body 142 includes a wall 148 surrounding the cavity 150. The control element 160 is received in the cavity 150. The inspection probe 110 may extend into the cavity 150. Other components may be housed within the cavity 150 and surrounded by the body 142. In various embodiments, the cavity 150 may be enclosed, for example, completely enclosed by the body 142. In various embodiments, the body 142 may be sealed and provide a sealing environment for components held within the cavity 150.

[0014] In an exemplary embodiment, the wall 148 forms a socket or receptacle 152 configured to receive a portion of the electrical connector 10. In the illustrated embodiment, the receptacle 152 is located at the front 144. The inspection probe 110 is located within the receptacle 152. For example, the inspection probe 110 may be surrounded by the wall 148 forming the receptacle 152. In an alternative embodiment, the inspection probe 110 may extend forward of the device housing 140. In an exemplary embodiment, the device housing 140 includes a partition wall 153 extending to the receptacle 152, separating the receptacle 152 into different chambers. Each chamber may receive a corresponding inspection probe 110. For example, partition walls 153 separate the inspection probes 110 from each other. Optionally, multiple inspection probes 110 may be located in each chamber. Walls 148 and / or partition walls 153 may include keying mechanisms, alignment mechanisms, or other types of positioning mechanisms to guide mating with the electrical connectors 10.

[0015] In an exemplary embodiment, the device housing 140 includes a mating end 154 configured to mate with an electrical connector 10. In the illustrated embodiment, the mating end 154 is located on the front portion 144. In alternative embodiments, other positions are possible. In various embodiments, the device housing 140 may include a plurality of mating ends configured to mate with different types of electrical connectors 10. For example, the mating ends may be provided on the front portion 144 and the rear portion 146 for mating with different electrical connectors 10. In an exemplary embodiment, the device housing 140 includes one or more latching mechanisms 155 for latching engagement with the electrical connector 10. In various embodiments, the latching mechanism 155 may be a flexible latch. In alternative embodiments, other types of latching mechanisms may be used, such as a fixed latch mechanism, a catch, a clip, or other types of latching mechanisms. In alternative embodiments, other types of fastening means, such as fasteners, straps, clips, or locks, may be used to secure the device housing 140 to the electrical connector 10.

[0016] In an exemplary embodiment, the device housing 140 includes a handle 158 for holding the device housing 140. The handle 158 may extend from one or more sides of the device housing 140. The handle 158 may extend from the front portion 144 and / or the rear portion 146. In the illustrated embodiment, the handle 158 is formed by a circumferential flange extending radially outward from the device housing 140, such as at the sides, top, and bottom of the device housing 140. In alternative embodiments, other positions are also possible. The handle 158 may include a finger grip or other mechanism to allow a user to hold the device housing 140.

[0017] Figure 4 is an exploded view of a connector health monitoring device 100 according to an exemplary embodiment. Figure 4 shows the device housing 140, the inspection probe 110, and the control element 160 according to an exemplary embodiment. The control element 160 and the inspection probe 110 may be retained by the device housing 140.

[0018] In the illustrated embodiment, the device housing 140 is a multi-part housing including a front housing 141 and a rear housing 143 configured to couple to each other. In an exemplary embodiment, a peripheral seal 145 is positioned between the front housing 141 and the rear housing 143, so as to provide a sealed interface between the front housing 141 and the rear housing 143. The peripheral seal 145 is configured to seal the cavity 150.

[0019] Each test probe 110 extends between a mating end 112 and a termination 114. The mating end 112 includes a mating interface 113 configured to mate with the testable contacts of the electrical connector 10. Optionally, the test probe 110 may have a graphite layer or other low-wear layer to improve the wear resistance of the connector interface and extend the service life of the electrical connector 10 and / or the test device, thereby reducing the frequency of maintenance. The termination 114 is configured to be electrically connected to the control element 160. In various embodiments, the test probe 110 may include a probe seal 115 at the termination 114, configured to seal to the device housing 140 or other components within the device housing 140. In the illustrated embodiment, the inspection probe 110 is a pin located at the mating end 112. In an alternative embodiment, the inspection probe 110 may be a socket located at the mating end 112. In an alternative embodiment, other types of inspection probes may be used. In various embodiments, the inspection probe 110 may include a touch protection cap at the mating end 112 to prevent accidental contact with the mating end 112. The inspection probe 110 may be cylindrical, such as having a diameter. In various embodiments, the diameter may be equal to the diameter of the charging pins of the electric vehicle's charging inlet, so that the connector health monitoring device mimics the mating interface of the electric vehicle's charging inlet to inspect the charging plug of the charging station.

[0020] The control element 160 is configured to be held by the device housing 140 and may be received in a cavity 150, such as between the front housing 141 and the rear housing 143. The control element 160 is configured to be operably coupled to the inspection probe 110, to receive signals from the inspection probe 110 and / or to transmit signals to the inspection probe 110. The control element 160 includes circuitry for measuring and analyzing signals from the inspection probe 110 to perform a health assessment of the electrical connector 10 during inspection.

[0021] In an exemplary embodiment, the control element 160 includes a printed circuit board 162, a control module 164 mounted on the printed circuit board 162, and a communication module 166 coupled to the printed circuit board 162. The control element 160 may include a positioning element for locating the connector health monitoring device 100 during inspection, for example, using a GPS or other location-based tracking device, such as locating the electrical connector being inspected. In an exemplary embodiment, the control element 160 may include a battery 168 for powering one or more components of the control element 160. The battery 168 is configured to be positioned in a cavity 150 of the device housing 140. The battery 168 may be rechargeable. The battery 168 may be accessible through the rear housing 143. The battery 168 may be covered by a battery cover 169, which may be removable for purposes such as charging the battery 168.

[0022] In an exemplary embodiment, the indicator 170 is coupled to a printed circuit board 162. Other types of output devices, such as a user interface (not shown), may be coupled to the printed circuit board 162 to provide output to the user. The indicator 170 may pass through an opening in the device housing 140, such as a rear housing 143. The indicator 170 may include an LED to provide a visual indicator to the user. In alternative embodiments, other types of indicators may be used.

[0023] The printed circuit board 162 includes a substrate having one or more layers. The printed circuit board 162 includes a circuit that includes conductors printed on one or more layers of the substrate. The circuit may include conductors, traces, vias, pads, or other types of circuit elements. One or more electrical components may be coupled to the circuit. In an exemplary embodiment, the test probe 110 is terminated to the printed circuit board 162. For example, the test probe 110 may be soldered to a circuit on the printed circuit board 162 or connected to the printed circuit board 162 via contacts. The substrate of the printed circuit board 162 may be fixed to the device housing 140 using fasteners or the like.

[0024] In an exemplary embodiment, the test probe 110 is coupled to a printed circuit board 162. The test probe 110 may be communicatively coupled to a test sensor 120. For example, the test sensor 120 may receive a signal from the test probe 110. The signal may be transmitted through one or more circuits on the printed circuit board 162. The test sensor 120 may be a separate component from the test probe 110 and / or the control module 164. In an alternative embodiment, the test sensor 120 may be integrated with the control module 164 or the test probe 110. The test probe 110 is used to measure one or more integrity characteristics of the testable contacts and / or electrical connector 10 in a separable connector interface 12. For example, the integrity assessment characteristics may include mating force, electrical characteristics, contact resistance, contact wear, emissivity, contact size, contact shape, and the presence of FOD. Optionally, multiple test probes 110 may be provided to test different integrity assessment characteristics of the separable connector interface 12 and / or to test different electrical terminals or different areas. In an exemplary embodiment, the test apparatus is configured for multi-parameter integrity assessment analysis of the separable connector interface 12. The test probes 110 may be force sensors configured to measure mating force at the test probe 110. The test probes 110 may be electrical sensors configured to measure current, voltage, amperage, etc. The inspection probe 110 may be a proximity sensor configured to measure the proximity and / or distance to inspectable contacts or other components of an electrical connector. The inspection probe 110 may also be an image sensor configured to analyze digital images or other types of images.

[0025] The control module 164 includes one or more electrical components such as a processor, IC components, memory devices, CMOS sensors, field-programmable gate arrays (FPGAs), and digital signal processors (DSPs). For example, the control module 164 includes one or more processors 165 for performing a health assessment of the electrical connector 10 based on signals received from the inspection probe 110. In exemplary embodiments, the control module 164 may be programmable. For example, the control module 164 may receive radio update signals to update analysis software or algorithms, for example. When the control module 164 is operating, it executes a program for analyzing the health assessment signals. For example, the control module 164 operates a program stored in one or more memories of the processor 165. Health assessments from data analysis may be used to allow / deny the connection or operation of electrical connectors, for periodic maintenance, or to assess efficiency (e.g., power conversion efficiency for predicting charging time based on the use of electrical connector 10).

[0026] Processor 165 may include computer system executable instructions, such as program modules, which are executed by the computer system. Generally, program modules may include routines, programs, objects, components, logic, data structures, etc., that perform a specific task or implement a specific abstract data type. The calculations may be performed in a distributed cloud computing environment, where tasks are executed by remote processing devices linked over a communication network. In a distributed cloud computing environment, program modules may reside on both local and remote computer system storage media, including memory storage devices.

[0027] In exemplary embodiments, various components such as memory and processor 165 may be communicatively coupled by a bus. The bus represents one or more of several types of bus structures, including a memory bus or memory controller, a peripheral bus, an accelerated graphics port, and a processor or local bus using any of the various bus structures.

[0028] The control module 164 may include various computer system-readable media. Such media may be any available media accessible by the control module 164, and may include both volatile and non-volatile media, and both removable and non-removable media. Memory may include computer system-readable media in the form of volatile memory, such as random access memory (RAM) and / or cache memory. The control module 164 may further include other removable / non-removable volatile / non-volatile computer system storage media. As just one example, a storage system for reading and writing to a non-removable non-volatile magnetic medium (not shown, typically called a “hard drive”) may be provided. Although not shown, a magnetic disk drive for reading and writing to removable non-volatile magnetic disks (e.g., "floppy disks") and an optical disk drive for reading and writing to removable non-volatile optical disks, such as CD-ROMs, DVD-ROMs, or other optical media, may be provided. In such cases, each may be connected to the bus by one or more data media interfaces. The memory may include at least one program product having a set of (e.g., at least one) program modules configured to perform the functions of embodiments of the present invention.

[0029] One or more programs, as well as an operating system, one or more application programs, other program modules, and program data, may be stored in memory. Each or several combinations of the operating system, one or more application programs, other program modules, and program data may include an implementation of a networking environment. Program modules generally perform functions and / or methods of embodiments of the subject matter described herein.

[0030] The control module 164 may also communicate with one or more external devices, such as via the communication module 166 of the control module 164, for data sharing and / or analysis by a remote inspection device. The communication module 166 may communicate with an electrical connector or a system incorporating the electrical connector 10 (e.g., a charging station or an electric vehicle). The communication module 166 may also communicate with a user via a mobile device (e.g., a mobile phone app or a vehicle display system). In various embodiments, the communication module 166 is configured to communicate wirelessly via Bluetooth®, Wi-Fi®, or other wireless protocols. In various other embodiments, the communication module 166 may communicate via other contacts such as the test probe 110 or the electrical connector 10. Health data may be shared with the electrical connector or the system associated with the electrical connector for maintenance purposes or to alert other users of the health of the electrical connector. External devices may include one or more devices that enable a user to interact with the system, such as a keyboard, pointing device, or display; one or more mobile devices (such as a mobile phone or mobile test unit); one or more devices associated with the electrical connector 10 (such as a charging station or electric vehicle); and / or any devices that enable the system to communicate with one or more other computing devices (e.g., a network card, modem, etc.). Such communication may be performed via input / output (I / O) interfaces. Furthermore, the control module 164 can communicate with one or more networks, such as a local area network (LAN), a general wide area network (WAN), and / or a public network (e.g., the Internet), via a network adapter. Other hardware and / or software components may be used in conjunction with the system components described herein. Examples, but not limited to, include microcode, device drivers, redundant processing units, external disk drive arrays, RAID systems, tape drives, and data archival storage systems.

[0031] As used herein, the term “processor” includes any processing device, such as a CPU (Central Processing Unit) and / or other forms of processing circuitry. Furthermore, the term “processor” may refer to two or more separate processors. The term “memory” includes memory associated with a processor or CPU, such as RAM (Random Access Memory), ROM (Read-Only Memory), fixed memory devices (e.g., hard drives), removable memory devices (e.g., diskettes), and flash memory. Furthermore, as used herein, the term “input / output interface” refers to, for example, an interface between one or more mechanisms for inputting data into a processing unit (e.g., a mouse) and one or more mechanisms for providing results associated with the processing unit (e.g., a printer). The processor 165, memory, and input / output interface may be interconnected via a bus as part of a data processing unit, for example. Suitable interconnections via a bus may also be provided for network interfaces, such as network cards, which may be provided for interfacing with a computer network, and for media interfaces, such as diskettes or CD-ROM drives, which may be provided for interfacing with suitable media.

[0032] Accordingly, computer software containing instructions or code for performing the subject matter of this specification may be stored in one or more associated memory devices (e.g., ROM, fixed memory, or removable memory), and when ready for use, it may be loaded in part or in whole (e.g., into RAM) and executed by the CPU. Such software may include, but is not limited to, firmware, resident software, microcode, and the like.

[0033] It should be noted that any of the methods described herein may include an additional step of providing a system comprising individual software modules embodied on a computer-readable storage medium. These modules may include, for example, any or all of the appropriate elements shown in a block diagram and / or described herein. For example, but not limited to, a module may include any, some, or all of the modules / blocks and / or submodules / subblocks described herein. The method steps may be performed using individual software modules and / or submodules of a system running one or more hardware processors, as described above. Furthermore, the computer program product may include a computer-readable storage medium having code adapted to be implemented to perform one or more method steps described herein, including the provision of a system having individual software modules.

[0034] In exemplary embodiments, the test probe 110 includes a pogo pin 118 for mating with a separable connector interface 12, such as an inspectable contact of an electrical connector 10. In alternative embodiments, the test probe 110 may include other types of test elements. In exemplary embodiments, the test probe 110 may be removable and replaceable. For example, the test probe 110 may be screw-coupled to the device housing 140 and / or control module 164 to allow for removal and replacement of the test probe 110. The test probe 110 may be removed and replaced to test different separable connector interfaces. For example, inspection probes 110 of different sizes (length and / or diameter) may be used. Inspection sensors having different types of inspection elements can be used by removing and replacing different inspection probes 110.

[0035] In an exemplary embodiment, the inspection sensor 120 associated with the inspection probe 110 includes a force measuring sensor 130 for detecting the mating force with the detachable connector interface 12. The force measuring sensor 130 may detect, for example, FOD by detecting the compressive force of the pogo pin 118.

[0036] In an exemplary embodiment, the inspection sensor 120 associated with the inspection probe 110 includes an electrical resistance measuring sensor 132 for detecting the electrical resistance with a separable connector interface 12, such as an inspectable contact. The electrical resistance measuring sensor 132 detects the electrical resistance between the pogo pin 118 and the inspectable contact.

[0037] In an exemplary embodiment, the inspection sensor 120 associated with the inspection probe 110 includes a position measuring sensor 134 for detecting the mating position of the inspection probe 110 with a detachable connector interface 12. The position measuring sensor 134 may include at least one of an optical sensor, a laser measuring sensor, and a proximity sensor for detecting the mating position of the inspection probe 110 with the detachable connector interface 12. The position measuring sensor 134 may detect the position of the inspection probe 110 relative to the housing of the inspectable contacts and / or electrical connector 10, such as the position of the pogo pin 118. The position measuring sensor 134 may also detect the length of the pogo pin 118 and / or the amount of compression of the pogo pin 118.

[0038] In an exemplary embodiment, the inspection probe 110 is mated to the separable connector interface 12 in a mating position. When FOD is present in the separable connector interface 12, the amount of compression of the pogo pin 118 in the mating position may differ compared to when no foreign matter is present. In an exemplary embodiment, the pogo pin 118 is configured to be electrically connected to an electrical terminal 17 in the separable connector interface 12. The measured electrical resistance between the pogo pin 118 and the electrical terminal 17 may change when FOD is present in the separable connector interface 12 compared to when no foreign matter is present in the separable connector interface 12. For example, if the FOD is made of a different material than the electrical terminal 17, the electrical resistance may change, which could indicate the presence of the FOD. If the FOD is made of a dielectric material such as plastic or rubber, the FOD is nonconductive, and the loss of electrical connection between the pogo pin 118 and the electrical terminal 17 would indicate the presence of the FOD. The connector integrity monitoring device 100 can be used for foreign object detection in separable interfaces.

[0039] In exemplary embodiments, the connector health monitoring device 100 integrates various detection or measurement techniques, such as resistance measurement and force measurement. The connector health monitoring device 100 may detect the presence of foreign objects by simultaneously measuring electrical resistance and applied force using a pogo pin 118. In exemplary embodiments, the pogo pin 118 is designed to have an end diameter that matches the socket opening for accurate FOD detection. The pogo pin 118 may feature a removable and replaceable screw-in head to fit a specific geometry. The pogo pin 118 can be made of plastic for FOD-only applications, and of metal for combinations of FOD and electrical measurement. In various other embodiments, the inspection probe 110 may be used to assess the integrity of the inspectable contacts and / or the housing of the electrical connector 10 by measuring other properties such as mating force, contact wear, or other characteristics.

[0040] In exemplary embodiments, the inspection probe 110 may measure the emission rate of the inspectable contact and assess the health of the inspectable contact. For example, a corresponding inspection sensor 120 may measure how efficiently the surface of the inspectable contact emits thermal radiation. The control module 164 uses emissivity measurement to determine contact wear. For example, the control module 164 may predict the amount of wear on the mating interface surface of the inspectable contact based on the difference in emissivity between silver and copper and determine whether maintenance is required. The control module 164 may perform projected area analysis for a more accurate wear assessment.

[0041] In exemplary embodiments, the connector health monitoring device 100 may incorporate an inspection probe 110 into the connector design, such as a charging inlet or charging plug used for charging, such as charging an electric vehicle. The connector health monitoring device 100 may leverage its inspection characteristics to automatically evaluate connector health, such as contact health, before full mating occurs, and / or detect the presence of FOD. The inspection probe 110 may be carefully calibrated to contact inspectable contacts for accurate evaluation of the health of inspectable contacts. The evaluation mechanism may be carried out through various means, such as electrical resistance measurement, mechanical pressure sensors, or optical sensors that monitor connections. Automated inspection methods eliminate the need for visual inspection, provide real-time feedback, and significantly reduce the risk of connector damage or system failure due to connector defects.

[0042] The connector health monitoring device 100 offers several advantages. It can improve accuracy by combining FOD detection with resistance and force measurements, providing a more comprehensive analysis of the interface condition. Its design versatility allows for both FOD-only applications and combined FOD / electrical measurement applications. The system's customizability allows it to adapt to various interface geometries. The connector health monitoring device 100 offers multi-parameter analysis capabilities, enabling the identification of various types of foreign objects and interface conditions by correlating pin position, electrical continuity, and applied force. The connector health monitoring device 100 performs health assessments on separable interfaces and provides a significant improvement over existing methods by performing a multifaceted analysis of the interface state. By integrating resistance measurement and force measurement capabilities in parallel with FOD detection, it enables more accurate and reliable identification of potential problems in critical connections. In various embodiments, image analysis may be additionally utilized to further improve the health assessment analysis.

[0043] The connector health monitoring device 100 can be a separate handheld inspection device. In various other embodiments, the connector health monitoring device 100 may be integrated into the connector interface, such as a charging inlet or charging plug. The connector health monitoring device 100 can be integrated into various types of connector systems, but is not limited to electric vehicle charging applications. The connector health monitoring device 100 may be used for detection in OEM assemblies, or by maintenance technicians or Tier I / II suppliers. The connector health monitoring device 100 can be used for user-initiated FOD detection, such as via a mobile phone or other mobile device interface. In various embodiments, the connector health monitoring device 100 may be incorporated into an assembly robot. For example, the connector health monitoring device 100 may be incorporated into a robot end effector that can inspect the interface during assembly. For example, the robot end effector may check for FOD before assembling the connector in a highly contaminated environment. The connector health monitoring device 100 may be used to inspect the charging port of a robot such as an automated guide vehicle (AGV) or other autonomous industrial vehicle, or to inspect a charging station associated with a vehicle before docking for charging.

[0044] Figure 5 is a front perspective view of a connector health monitoring device 100 according to an exemplary embodiment. In the illustrated embodiment, the connector health monitoring device 100 includes a camera 180 at the mating end 112 for photographing the electrical connector 10. The camera 180 is operably coupled to a control element 160.

[0045] Images from camera 180 may be analyzed by control element 160 to provide an assessment of the integrity of the electrical connector 10. For example, images may be analyzed to identify the location of inspectable contacts relative to each other or to the connector housing. Images may be analyzed to determine the size of the inspectable contacts and / or the spacing between the inspectable contacts and the connector housing. Images may be analyzed to identify FODs in the mating interface. Images may be analyzed to identify damage, wear, or other problems caused by the inspectable contacts. Images may be used in addition to other inspection signals from the inspection probe 110 to provide an assessment of the integrity of the electrical connector 10. Images from the camera may be used to position the connector health monitoring device 100 relative to the electrical connector 10. For example, in the case of automated inspection (e.g., the connector health monitoring device 100 is integrated into the end effector of an assembly robot), the images may be used to align the connector health monitoring device 100 with the electrical connector 10 during inspection. Other types of alignment mechanisms may be used for aligning parts together or for aligning the camera 180 with the mating interface, such as a laser alignment mechanism or a proximity detector.

[0046] The control element 160 may analyze the image using an image processing module and / or an image processing algorithm and / or image processing software. Image processing may include boundary detection, color detection, illumination detection, image segmentation, edge detection, color mapping, feature extraction, image enhancement, color space conversion, illumination correction, etc. The image may be analyzed by the control element 160 or by a remote device. For example, the image may be sent to another device and / or the cloud for offline analysis. The control element 160 or other device used for analysis may include an AI learning module to improve or enhance image analysis based on the image.

[0047] In the illustrated embodiment, the camera 180 is located on the partition wall 150. In alternative embodiments, other positions are possible, and the camera 180 is positioned to view components of the electrical connector 10, such as the inspectable contacts, housing, or other parts of the electrical connector 10. The images may be analyzed to identify FOD within and / or around the contacts, damaged or missing contacts, damaged parts of the housing, or other factors that may affect the integrity of the electrical connector 10. The images may be analyzed to observe or predict contact wear. The images may be analyzed to find soot, plastic, or other debris on the contacts that may affect the conductivity of the contacts.

[0048] In an exemplary embodiment, the connector health monitoring device 100 includes an illumination element 182 held by a device housing 140. The illumination element is configured to illuminate the electrical connector 10, such as the inspectable contacts, housing, or other components of the electrical connector 10. The illumination element 182 is used to improve image acquisition by the camera 180. The illumination element 182 may measure ambient light and determine its intensity, color, or other illumination characteristics to improve image acquisition by the camera 180.

[0049] Figure 6 is a rear perspective view of a connector health monitoring device 100 according to an exemplary embodiment in the illustrated model, which includes a user interface 190 coupled to a device housing 140. For example, the user interface 190 may be incorporated into a rear housing 143 and accessible from the rear 146.

[0050] In exemplary embodiments, the user interface 190 includes a display 192 configured to display information to the user, such as operating status, health assessment data, communication status, battery status, or other information. In various embodiments, the display 192 may be a touchscreen that allows user control. In other various embodiments, the user interface 190 may include other inputs, such as a keypad, buttons, sliders, dials, or other types of user input. In alternative embodiments, user input may be made via a remote device, such as a mobile device communicatively coupled to the connector health monitoring device 100.

[0051] Figure 7 is a front perspective view of the connector health monitoring device 100 according to an exemplary embodiment. Figure 8 is a rear perspective view of the connector health monitoring device 100 shown in Figure 7. In the illustrated embodiment, the connector health monitoring device 100 includes a first mating interface 102a on the front 144 and a second mating interface 102b on the rear 146. The first mating interface 102a may be a NACS charging interface, and the second mating interface 102b may be a CCS1 charging interface. In alternative embodiments, other types of interfaces may be used. By providing different types of mating interfaces on the same connector health evaluation device, it becomes possible to inspect different types of electrical connectors using the same connector health evaluation device.

[0052] Figure 9 shows a charge health monitoring system 70 according to an exemplary embodiment. The charge health monitoring system 70 includes a connector health monitoring device 100. The monitoring device 100 is used to monitor the health of the charging terminals used to charge the electric vehicle 80. The charge health monitoring system 70 measures the health of the charging interface when the vehicle 80 is connected to the charging station 20.

[0053] The connector health monitoring device 100 may be used to detect the presence of foreign objects in the charging interface before and / or during charging. The connector health monitoring device 100 may be used to evaluate the health of the charging terminals in the charging interface before and / or during charging. The charging health monitoring system 70 may provide a signal to allow or deny charging based on the measured health and / or FOD detection of its particular separable interface. The charging health monitoring system 70 mitigates dissatisfaction due to slow charging speed, potential harmful user intervention (shaking the charging plug to increase charging speed), or damage to the inlet or charging plug due to poor interface health.

[0054] The connector health monitoring device 100 may be incorporated into the electric vehicle 80 and / or the charging station 20 for charging the electric vehicle 80 to monitor the health of charging components, for example, to control charging operations. For example, the connector health monitoring device 100 may allow or deny charging operations based on the health of the charging terminals and / or based on FOD detection. In an exemplary embodiment, the connector health monitoring device 100 measures the interfacial resistance at the interface of the charging terminals to determine the health of the charging components and / or detect the presence of FOD. If the interface resistance is too high, the connector health monitoring device 100 will refuse to perform the charging operation. In this case, the operator may use another charging station 20 and / or repair or replace the charging components to improve the charging operation.

[0055] The electric vehicle 80 includes a charging inlet 82 having a charging terminal 90. In an exemplary embodiment, the charging inlet 82 includes a receptacle configured to receive a charging plug. In various embodiments, the charging inlet 82 can operate as a standard type charging inlet, such as an SAE J1772 inlet. In an exemplary embodiment, the charging terminal 90 is a pin terminal; however, in alternative embodiments, other types of charging terminals may be used. The charging inlet 82 is mounted on the vehicle 80. The charging inlet 82 is electrically connected to the battery 86 of the electric vehicle 80. The charging terminal 90 recharges the battery 86 by being powered from the charging station 20. A connector health monitoring device 100 may be incorporated into the charging inlet, such as being integrated with the charging terminal 90.

[0056] The charging station 20 includes a charging plug 40 at the end of a charging cable 42. The charging plug 40 is configured to mate with a charging inlet 82. The charging station 20 supplies power to the charging plug 40 to charge the electric vehicle 80. The charging plug 40 may be a Level 1 charger, a Level 2 charger, or a Level 3 charger. In an exemplary embodiment, the charging plug may be a DC fast charger. The charging plug 40 may be any type of electric vehicle charging interface having an arrangement of charging terminals, such as a combined charging system (CCS) having both AC and DC charging terminals. The charging plug 40 includes a handle 44 for holding the charging terminals 50. In an exemplary embodiment, the charging terminal 50 is a charging socket. The charging terminal 50 is received by a receptacle 84 and configured to mate with the charging terminal 90 of a charging inlet 82.

[0057] In various embodiments, the connector health monitoring device 100 is part of an electric vehicle 80. For example, the connector health monitoring device 100 may be part of a charging inlet 82. The connector health monitoring device 100 may be part of a battery system. In other various embodiments, the connector health monitoring device 100 is part of a charging station 20. For example, the connector health monitoring device 100 may be part of a charging plug 40. The connector health monitoring device 100 may control the power supply from the charging station 20 to the charging inlet 82. For example, the connector health monitoring device 100 may stop the charging operation if it determines that the health of the charging components in the charging interface is unhealthy and / or if FOD is detected. For example, if the electrical resistance of the charging interface is high due to damage or deterioration, or due to the presence of foreign matter, the charging operation may be refused. In an exemplary embodiment, the connector health monitoring device 100 enables individual consumers, vehicle owners, charging station maintenance operators, or other individuals to assess the health of the charging plug 40 and determine whether the charging plug 40 or its components require maintenance and / or replacement. The connector health monitoring device 100 measures the connection resistance of the charging plug 40 to determine the health of the charging terminal 50. In an exemplary embodiment, the connector health monitoring device 100 compares the measured resistance to a known connection database ranging from good to bad to provide a health index for a particular charging terminal 50 for the user to determine whether the charging terminal 50 requires maintenance or replacement. The connector health monitoring device 100 may provide the user with an output indicating the health of the charging terminal 50 and / or the presence of FOD, which may be displayed in the charging station 20 and / or in the electric vehicle 80 and / or on a mobile device.

Claims

1. A connector health monitoring device (100) for evaluating the health of an electrical connector (10), wherein the connector health monitoring device is A device housing (140) including a main body (142) that forms a cavity (150), wherein the device housing has a mating end (112) configured to mate with the electrical connector, A control element (160) received in the cavity, wherein the control element includes a processor (165) for performing a health assessment of the electrical connector, An inspection probe (110) held by the device housing, the inspection probe includes a mating interface (102) for mating with an inspectable contact of the electrical connector, the inspection probe is positioned at the mating end for mating with the inspectable contact, and the inspection device is operably coupled to the control element, the inspection probe (110) and A connector health monitoring device (100) is provided.

2. The connector health monitoring device (100) according to claim 1, wherein the control element (160) provides an output indicating the health of the electrical connector (10) based on the health evaluation.

3. The connector health monitoring device (100) according to claim 1, wherein the device housing (140) includes a wall (148) that forms a socket at the mating end (112), and the inspection probe (110) is located in the socket.

4. The connector health monitoring device (100) according to claim 1, wherein the inspection probe (110) is a first inspection probe, and the connector health monitoring device further comprises a second inspection probe on the mating end (112) for mating with a second inspectable contact of the electrical connector (10).

5. The connector health monitoring device (100) according to claim 1, wherein the mating end (112) is a first mating end located on the first side of the device housing (140), the device housing includes a second mating end on the second side of the device housing, the connector health monitoring device further comprises a second inspection probe (110) on the second mating end, the first mating end has a first layout for mating with a first type of electrical connector (10), and the second mating end has a second layout for mating with a second type of electrical connector.

6. The connector health monitoring device (100) according to claim 5, wherein the first mating end (112) is configured to mate with a CCS1 charging connector, and the second mating end is configured to mate with a NACS charging connector.

7. The connector health monitoring device (100) according to claim 1, wherein the control element (160) includes a communication module (166) configured to communicate wirelessly, and the communication module transmits a health evaluation signal based on the health evaluation to a remote device.

8. The connector health monitoring device (100) according to claim 1, further comprising a camera (180) held by the device housing (140) and configured to photograph the inspectable contacts of the electrical connector (10), wherein the control element (160) determines the health assessment based on the image from the camera.

9. The connector health monitoring device (100) according to claim 8, further comprising an illumination element (182) held by the device housing (140) and configured to illuminate the inspectable contacts of the electrical connector (10).

10. The connector health monitoring device (100) according to claim 1, further comprising a wear sensor configured to identify wear on the inspectable contacts of the electrical connector (10), wherein the control element (160) determines the emissivity of the inspectable contacts based on a signal from the wear sensor and predicts wear on the inspectable contacts of the electrical connector.

11. The connector health monitoring device (100) according to claim 1, further comprising a user interface (190) coupled to the device housing (140).

12. The connector health monitoring device (100) according to claim 1, wherein the control element (160) includes a first sensor for detecting a first health evaluation characteristic of the inspectable contact and a second sensor for detecting a second health evaluation characteristic of the inspectable contact that is different from the first health evaluation characteristic.

13. The connector health monitoring device (100) according to claim 1, wherein the device housing (140) is handheld.

14. The connector health monitoring device (100) according to claim 1, further comprising a battery (168) that is coupled to the control element (160) to supply power to the connector health monitoring device.

15. The connector health monitoring device (100) according to claim 1, wherein the inspection probe (110) includes a pogo pin (118) configured to interface with the inspectable contact.

16. The connector health monitoring device (100) according to claim 15, wherein the pogo pin (118) measures at least one of the mating force with the inspection probe (110) and electrical resistance.

17. The connector health monitoring device (100) according to claim 1, further comprising a proximity detector operably coupled to the control element (160) and configured to detect the degree of proximity to the electrical connector (10) and to control the control element.

18. The connector integrity monitoring device (100) according to claim 1, wherein the inspection probe (110) monitors for foreign matter in the mating interface (102) with the inspectable contact.

19. The connector health monitoring device (100) according to claim 1, wherein the inspection probe (110) includes a low-wear layer on the mating interface (102) to improve wear resistance.

20. A connector health monitoring device (100) for evaluating the health of an electrical connector (10), wherein the connector health monitoring device is A device housing (140) comprising a body (142) forming a cavity (150), wherein the device housing has a first mating end (112) configured to mate with the electrical connector at a first end of the device housing, the device housing includes a second mating end on a second side of the device housing, the first mating end having a first layout for mating with a first type of the electrical connector, and the second mating end having a second layout for mating with a second type of the electrical connector, A first inspection probe (110) held by the device housing, wherein the first inspection probe includes a first mating interface (102a) at the first mating end for mating with an inspectable contact of the first type of electrical connector, A second inspection probe held by the device housing, wherein the second inspection probe includes a second mating interface (102b) at the second mating end for mating with an inspectable contact of the second type of electrical connector (18), A control element (160) received in the cavity, wherein the control element is operably coupled to the first inspection probe to receive a signal from the first inspection probe, and is operably coupled to the second inspection probe to receive a signal from the second inspection probe, and the control element includes a processor (165) for performing a health assessment of the electrical connector (10) based on the signals received from the first inspection probe or the second inspection probe. A connector health monitoring device (100) is provided.

21. The connector health monitoring device (100) according to claim 20, wherein the first mating end (112) is configured to mate with a CCS1 charging connector, and the second mating end is configured to mate with a NACS charging connector.

22. A connector health monitoring device (100) for evaluating the health of an electrical connector (10), wherein the connector health monitoring device is A device housing (140) including a main body (142) that forms a cavity (150), wherein the device housing has a mating end (112) configured to mate with the electrical connector, A test probe (110) held by the device housing, the test probe includes a mating interface (102) for mating with a testable contact of the electrical connector, and the test probe is positioned at the mating end for mating with the testable contact. A camera (180) held by the device housing and configured to photograph the inspectable contacts of the electrical connector, A control element (160) received in the cavity, wherein the control element is operably coupled to the inspection probe to receive signals from the inspection probe, and the control element is operably coupled to the camera to receive images from the camera, and the control element includes a processor (165) for performing a health assessment of the electrical connector based on the signals from the inspection probe and the images from the camera. A connector health monitoring device (100) is provided.

23. A method for monitoring the integrity of a separable connector interface (12) of an electrical connector, wherein the method is: To provide a connector health monitoring device (100) comprising a device housing (140) having a mating end (112) configured to mate with the electrical connector, wherein the connector health monitoring device includes an inspection probe (110) held by the device housing and having a mating interface (102) at the mating end for mating with the inspectable contacts of the electrical connector, and the connector health monitoring device includes a control element (160) received in the cavity and operably coupled to the inspection probe to receive signals from the inspection probe. The inspection probe is mated with the inspectable contacts of the electrical connector in the separable connector interface, The inspection probe measures the integrity evaluation characteristics of the inspectable contact using the sensor of the control element, Based on the measured integrity assessment characteristics, the control element generates a integrity assessment of the inspectable contact. Methods that include...

24. The method according to claim 23, further comprising transmitting the health assessment to a remote device.

25. The method according to claim 23, further comprising using a camera (180) to photograph the inspectable contact before fitting the inspection probe (110) to the inspectable contact, and generating a health assessment of the inspectable contact in the control element (160) based on the image of the inspectable contact.

Images