Connector health monitoring system

Abstract

This provides a reliable method for evaluating connector integrity in separable mating interfaces. [Solution] A connector health monitoring system for health evaluation testing of electrical connectors includes a connector health monitoring device 100, which includes a device housing 140 and an inspection probe 110 held by the device housing, the inspection probe being positioned at the mating end to mate with an inspectable contact of the electrical connector to generate inspection data. A communication module transmits the inspection data. The connector health monitoring system includes a health evaluation device which is communicatively coupled to the connector health monitoring device and receives inspection data from the communication module of the connector health monitoring device. The health evaluation device includes an analysis module which includes a processor for performing a health evaluation of the electrical connector based on the inspection data.

Description

Technical Field

[0001] This application claims the priority benefit of U.S. Application No. 63 / 783,559 filed on April 4, 2025, the subject matter of which is hereby incorporated in its entirety into the present specification by reference.

[0002] The present subject matter 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 objects or debris at a separable connector interface is problematic and 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 (EV) poses significant challenges, particularly in ensuring safe charging at charging interfaces. Such an interface where a vehicle connects to a charging station is an example of a high-voltage interface that is susceptible to damage or degradation in the field as it is exposed to varying amounts of environmental exposure. Charging components are made robust to handle charging plugs of varying quality and condition. There is a need to develop solutions for detecting the health of connection systems and enabling predictive maintenance. One of the main indicators suggesting a poor connection is increased heat loss that reduces overall charging efficiency. Reduced charging efficiency leads to increased charging power or extended charging duration. The increased costs resulting from such poor connections are passed on to vehicle owners, resulting in a degraded end-user experience. In some cases, poor connections may cause irreversible damage to the vehicle inlet that necessitates 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 Initiative] [Problems that the invention aims to solve]

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

[0005] In one embodiment, a connector health monitoring system is provided for health evaluation testing of electrical connectors. The connector health monitoring system includes a connector health monitoring device, which includes a device housing and an inspection probe held by the device housing. The device housing includes a mating end configured to mate with an electrical connector. The inspection probe is positioned at the mating end to mate with the inspectable contacts of the electrical connector to generate inspection data. The connector health monitoring device includes a communication module configured to transmit the inspection data. The connector health monitoring system includes a health evaluation device communicatively coupled to the connector health monitoring device. The health assessment device includes a communication module configured to receive inspection data from the communication module of the connector health monitoring device. The health assessment device also includes an analysis module (analyzer module) containing a processor for performing a health assessment of the electrical connector based on the inspection data.

[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 system 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] Figure 5 shows a rear perspective view of the connector health monitoring device according to an exemplary embodiment. [Figure 7] This is a front view of a health assessment device according to an exemplary embodiment. [Figure 8] This figure shows a connector health monitoring system according to an exemplary embodiment. [Modes for carrying out the invention]

[0008] Figure 1 shows a connector health monitoring system 70 according to an exemplary embodiment. The connector health monitoring system 70 includes a connector health monitoring device 100 and a health evaluation device 200. The health evaluation device 200 is separate from and independent of the connector health monitoring device 100. The connector health monitoring device 100 is communicatively coupled to the health evaluation device 200. For example, the connector health monitoring device 100 may communicate wirelessly with the health evaluation device 200. The connector health monitoring device 100 is used to monitor or inspect one or more electrical connectors 10. The health assessment device 200 is used to analyze the inspection data generated by the connector health monitoring device 100 in order to determine the health assessment of the electrical connector 10 based on the inspection data.

[0009] The connector health monitoring system 70 is used to evaluate the health of the mating interface of one or more electrical connectors 10. For example, the connector health monitoring system 70 may evaluate the health of the separable connector interface 12 of the electrical connector 10 against foreign object debris (FOD) 14 and / or wear of the contacts or terminals of the electrical connector and / or the operating condition of the contacts or terminals of the electrical connector. The connector health monitoring system 70 provides health assessments to user and / or stakeholders' networks to, for example, identify the health or functionality of a specific electrical connector 10. For example, a user or stakeholder may schedule maintenance or repair of the electrical connector 10 based on the health assessment. The connector health monitoring system 70 can facilitate scheduling preventative maintenance of components such as charging devices in a charging system, thereby reducing downtime. A user or stakeholder may utilize other electrical connectors 10 based on the health assessment. The health assessment may be displayed on the health assessment device 200 or distributed more broadly to another remote device, computer, server, network, cloud, or other destination.

[0010] In an exemplary embodiment, the electrical connector 10 in the separable connector interface 12 includes a first electrical connector 16 and a second electrical connector 18. The connector health monitoring system 70 may be used to inspect the interface of the first electrical connector 16 and / or the second electrical connector 18. In an exemplary embodiment, the connector health monitoring system 70 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. For example, the connector health monitoring device 100 may be mated with the first electrical connector 16 and / or the second electrical connector 18 for health evaluation of the corresponding electrical connectors 16, 18.

[0011] 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.

[0012] In exemplary embodiments, the connector health monitoring device 100 may include one or more test probes 110. Each test probe 110 may be used to measure one or more health assessment characteristics of the testable contacts and / or electrical connector 10 in the 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.

[0013] The inspection data from the inspection probe 110 is configured to be transmitted to the health evaluation device 200 by wireless communication or the like. The communication may be short-range communication via Bluetooth® or Wi-Fi® between the connector health monitoring device 100 and the health evaluation device 200 when the health evaluation device 200 is in the vicinity of the connector health monitoring device 100 (for example, both devices are located at the electrical connector 10). In various other embodiments, when the connector health monitoring device 100 and the health evaluation device 200 are in different locations, the communication may be configured for long-range communication, such as cellular wireless communication via a cellular network. After the health assessment device 200 receives the inspection data, it performs a health assessment based on the inspection data and makes a determination about the quality or operating status of the electrical connector 10. In various embodiments, the raw inspection data may be transmitted from the connector health monitoring device 100 to the health assessment device 200. For example, the inspection data may be transmitted unprocessed. However, in various other embodiments, the connector health monitoring device 100 may include one or more processors configured to process the inspection data, and the processed inspection data is transmitted to the health assessment device 200 for analysis and determination of the connector's health assessment by the health assessment device 200.

[0014] In various embodiments, the connector health monitoring device 100 is a handheld device. For example, the connector health monitoring device 100 may be a handheld, pluggable device configured to be inserted into or mated with the electrical connector 10. In various other embodiments, the connector health monitoring device 100 may be incorporated into another component, such as a system component associated with the electrical connector 10, to inspect the electrical connector 10 during the inspection process. The connector health monitoring device 100 may be integrated with the electrical connector 16 to inspect the electrical connector 18, or vice versa. The connector health monitoring device 100 may be incorporated into an assembly robot, such as being incorporated into an end effector at the end of the robot's arm to inspect the electrical connector 10 immediately after its assembly.

[0015] In various embodiments, the connector health monitoring system 70 is used to evaluate the health of power connectors, such as connectors used in charging applications. For example, the connector health monitoring system 70 may be used to evaluate the health of charging plugs and / or charging inlets in vehicles such as electric vehicles. However, the connector health monitoring system 70 is not limited to use in charging applications or power connectors, and may be used in other types of electrical connectors in a variety of other applications.

[0016] 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 a charging inlet of an electric vehicle, such that the connector health monitoring device mimics the mating interface of the charging inlet of the electric vehicle to inspect a charging plug of a charging station. For example, the mating interface 102 may be a CCS1 charging interface, a NACS charging interface, or another type of standard charging interface for electric vehicles.

[0017] The connector health monitoring device 100 includes a device housing 140 that retains one or more of the inspection probes 110. The device housing 140 retains a control element 160 operably coupled to the inspection probes 110. The control element 160 may include one or more processors for processing inspection data. The control element 160 may include one or more sensors associated with the inspection probes to receive inspection data. In an exemplary embodiment, the connector health monitoring device 100 may include one or more indicators 170 operably coupled to the control element 160. The indicators 170 may provide an operator with a visual indicator, an auditory indicator, or other type of indicator that indicates the connector health of the electrical connector 10 during an inspection operation. For example, the indicators 170 may include LED lights that provide a visual indicator to the operator, such as a green light and a red light that respectively indicate a good state or a bad state. In alternative embodiments, other types of indicators may be used.

[0018] The device housing 140 includes a body 142 extending between a front portion 144 and a rear portion 146 of the device housing 140. In the illustrated embodiment, the indicator 170 is provided on the rear portion 146. In alternative embodiments, other positions are also possible. In an exemplary embodiment, 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 in which a plurality of parts are coupled to each other to form the device housing 140. The body 142 includes a wall 148 surrounding a cavity 150. The control element 160 is received in the cavity 150. The test probe 110 may extend into the cavity 150. Other components may be accommodated within the cavity 150 and surrounded by the body 142. In various embodiments, the cavity 150 may be enclosed, for example, completely surrounded by the body 142. In various embodiments, the body 142 may be sealed to provide a sealed environment for the components held within the cavity 150.

[0019] 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 portion 144. The test probe 110 is positioned within the receptacle 152. For example, the test probe 110 may be surrounded by the wall 148 forming the receptacle 152. In alternative embodiments, the test probe 110 may extend forward of the device housing 140. In an exemplary embodiment, the device housing 140 includes a partition wall 153 extending into the receptacle 152 that divides the receptacle 152 into different chambers. Each of the chambers may receive a corresponding test 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.

[0020] 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.

[0021] In exemplary embodiments, 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 144 and / or rear 146. In the illustrated embodiment, the handle 158 is formed by a circumferential flange extending radially outward from the device housing 140, such as on the sides, top, and bottom of the device housing 140. Other locations are possible in alternative embodiments. The handle 158 may include a finger grip or other mechanism to allow the user to hold the device housing 140.

[0022] Figure 4 is an exploded view of a connector health monitoring device 100 according to an exemplary embodiment. Figure 4 shows a device housing 140, an inspection probe 110, and a control element 160 according to an exemplary embodiment. The control element 160 and the inspection probe 110 may be held by the device housing 140.

[0023] In the illustrated embodiment, the device housing 140 is a multi-component housing including a front housing 141 and a rear housing 143 configured to connect with each other. In an exemplary embodiment, a peripheral seal 145 is located between the front housing 141 and the rear housing 143, thereby providing a sealed interface between the front housing 141 and the rear housing 143. The peripheral seal 145 is configured to seal the cavity 150.

[0024] 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.

[0025] 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. In exemplary embodiments, the control element 160 includes circuitry or components for processing signals or inspection data from the inspection probe 110. The control element 160 may also include circuitry or components for measuring and / or analyzing the inspection data. The control element 160 may also include circuitry or components for performing a health assessment of the electrical connector 10 during inspection operation.

[0026] 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 also include a positioning element 167 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 also 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.

[0027] 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.

[0028] 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.

[0029] 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 one or more test sensors 120. For example, the test sensor 120 may receive signals from the test probe 110. The signals may be transmitted through one or more circuits on the printed circuit board 162. The test probe 110 may be a separate component from the test sensor 120 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 and / or the test sensor 120 are 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 and / or test sensors 120 may be provided to test different integrity assessment characteristics and / or to test different electrical terminals or different areas of the separable connector interface 12. In an exemplary embodiment, the test apparatus is configured for multi-parameter integrity assessment analysis of the separable connector interface 12. The test sensor 120 may be a force sensor configured to measure mating force on the test probe 110. The test sensor 120 may be an electrical sensor configured to measure current, voltage, amperage, etc. The inspection sensor 120 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 sensor 120 may also be an image sensor configured to analyze digital images or other types of images.

[0030] 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 processing inspection data. 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. During operation, the control module 164 may run programs to process and / or analyze inspection data, such as for health assessment. For example, the control module 164 runs a program stored in one or more memories of the processor 165. Data analysis may be used to allow / deny the connection or operation of electrical connectors, for routine maintenance, or to assess efficiency (e.g., power conversion efficiency for predicting charging time based on the use of electrical connector 10).

[0031] 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.

[0032] 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.

[0033] 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.

[0034] One or more programs may be stored in memory, as well as in the operating system, one or more application programs, other program modules, and program data. 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.

[0035] 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. In an exemplary embodiment, the communication module 166 communicates with a health assessment device 200. For example, the communication module 166 may transmit inspection data to the health assessment device 200. The communication module may transmit raw / unprocessed inspection data or processed inspection data. The communication module 166 may also communicate with the electrical connector 10 or a system incorporating the electrical connector 10 (e.g., a charging station or an electric vehicle). The communication module 166 may communicate with the 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 or other signals may be shared with the electrical connector or a 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 device that enables 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.

[0036] 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, 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.

[0037] 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.

[0038] 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.

[0039] 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.

[0040] 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. Data from the force measuring sensor 130 may be transmitted by the communication module 166 to a health assessment device 200 or the like as inspection data or sensor data.

[0041] In an exemplary embodiment, the inspection sensor 120 associated with the inspection probe 110 includes an electrical resistance measuring sensor 132 for detecting 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. Data from the electrical resistance measuring sensor 132 may be transmitted by the communication module 166 to a health assessment device 200 or the like as inspection data or sensor data.

[0042] 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. The data from the position measurement sensor 134 may be transmitted by the communication module 166 to a health assessment device 200 or the like as inspection data or sensor data.

[0043] 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.

[0044] 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.

[0045] In exemplary embodiments, the inspection probe 110 may measure the emissivity of the inspectable contact and evaluate 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 emissivity measurement may determine inspection data transmitted by the communication module 166 to a health evaluation device 200 or the like to determine contact wear. In various other embodiments, the control module 164 may use the 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.

[0046] 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.

[0047] The connector health monitoring device 100 offers several advantages. The connector health monitoring device 100 can improve accuracy by combining FOD detection with resistance and force measurements, providing a more comprehensive analysis of the interface condition. In various embodiments, the connector health monitoring device 100 may include a camera (not shown) for photographing the electrical connector 10. Inspection data may be determined from the images from the camera, and the images may be analyzed for health assessment. The design's versatility allows for both FOD-only applications and combined FOD / electrical measurement applications. The system's customizability enables adaptation to various interface geometries. The connector health monitoring device 100 provides multi-parameter analysis capabilities, allowing for 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.

[0048] 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.

[0049] Figure 5 is a front perspective view of the connector health monitoring device 100 according to an exemplary embodiment. Figure 6 is a rear perspective view of the connector health monitoring device 100 shown in Figure 5. In the illustrated embodiment, the connector health monitoring device 100 includes a first mating interface 102a located at the front 144 and a second mating interface 102b located at 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 monitoring device, it becomes possible to inspect different types of electrical connectors using the same connector health monitoring device.

[0050] Figure 7 is a front view of a health assessment device 200 according to an exemplary embodiment. The health assessment device 200 includes a device housing 240 that holds an analysis module 260 for performing a health assessment of an electrical connector based on inspection data. The health assessment device 200 is configured to communicate with a connector health monitoring device 100 and to receive inspection data from the connector health monitoring device 100. The analysis module 260 may include one or more processors for processing the inspection data. The analysis module 260 may include one or more sensors for receiving and analyzing the inspection data. The health assessment device 200 is configured to generate an output indicating the health assessment of the electrical connector 10. The output may be displayed or shown on the health assessment device 200. The output may be returned to the connector health monitoring device 100. The output may be sent to a system or component associated with the electrical connector 10 (e.g., a charging system or a vehicle or assembly robot). The output may be sent to another remote device, computer, server, network, cloud, or other recipient. The output may be used to allow / deny connection or operation of the electrical connector, for routine maintenance of the electrical connector, to assess the efficiency of the electrical connector (e.g., power conversion efficiency for predicting charging time based on the use of the electrical connector 10), or for other purposes.

[0051] The device housing 240 includes a body 242 extending between the front 244 and rear 246 of the device housing 240. In exemplary embodiments, the body 242 may be made from a dielectric material such as a plastic material. However, the body 242 may be made from other materials such as metal. The body 242 may be a multi-part body having multiple components that are coupled together to form the device housing 240. The main body 242 includes a wall 248 surrounding the cavity 250. The analysis module 260 is received in the cavity 250. Other components may be housed within the cavity 250 and surrounded by the main body 242. In various embodiments, the cavity 250 may be enclosed, for example, completely enclosed by the main body 242. In various embodiments, the main body 242 may be sealed and provide a sealed environment for components held within the cavity 250.

[0052] The analysis module 260 is configured to be held by the device housing 240 and may be received in the cavity 250. The analysis module 260 receives inspection data from the connector health monitoring device 100. In exemplary embodiments, the analysis module 260 includes circuitry or components for processing the inspection data. The analysis module 260 may include circuitry or components for measuring and / or analyzing the inspection data. The analysis module 260 may include circuitry or components for performing a health assessment of the electrical connector 10 during inspection operation.

[0053] In an exemplary embodiment, the analysis module 260 includes a printed circuit board 262, a control module 264 mounted on the printed circuit board 262, and a communication module 266 coupled to the printed circuit board 262. The analysis module 260 may include a positioning element 267 for locating the health assessment device 200 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 analysis module 260 may include a battery 268 for powering one or more components of the analysis module 260. The battery 268 is configured to be positioned in a cavity 250 of the device housing 240. The battery 268 may be rechargeable.

[0054] In an exemplary embodiment, the health assessment device 200 includes a user interface 290 coupled to a device housing 240. The user interface 290 may be coupled to a printed circuit board 262 and / or an analysis module 260, receiving outputs from the analysis module 260 and providing outputs to the user. The user interface 290 may be located on the front of the device housing 240. The user interface 290 includes a display 292 configured to display information to the user, such as operating status, data indicating health assessment, communication status, battery status, or other information to facilitate interpretation of test results and device status. In various embodiments, the display 292 may be a touchscreen to enable user control. In other various embodiments, the user interface 290 may include other inputs, such as a keypad, buttons, sliders, dials, or other types of user input. In alternative embodiments, user input may be provided via a remote device, such as a mobile device communicatively coupled to the health assessment device 200.

[0055] The printed circuit board 262 includes a substrate having one or more layers. The printed circuit board 262 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. The substrate of the printed circuit board 262 may be fixed to the device housing 240 using fasteners or the like.

[0056] In exemplary embodiments, the analysis module 260 may include one or more inspection sensors 220. For example, the inspection sensors 220 may receive inspection data transmitted from the connector health monitoring device 100. The signals may be transmitted via one or more circuits on the printed circuit board 262. The inspection sensors 220 may be a separate component from the control module 264. In alternative embodiments, the inspection sensors 220 may be integrated with the control module 264. The inspection sensors 220 are used to measure one or more health assessment characteristics of the inspectable contacts and / or electrical connector 10. For example, health assessment characteristics may include mating force, electrical characteristics, contact resistance, contact wear, emissivity, contact size, contact shape, and the presence of FOD. Optionally, multiple inspection sensors 220 may be provided to inspect different integrity characteristics and / or different electrical terminals or areas of the electrical connector 10. In an exemplary embodiment, the inspection device is configured for multi-parameter integrity analysis of the electrical connector 10. The inspection sensors 220 may be force sensors configured to measure mating force at the inspection probe 110. The inspection sensors 220 may be electrical sensors configured to measure current, voltage, amperage, etc. The inspection sensors 220 may be proximity sensors configured to measure proximity and / or distance to inspectable contacts or other components of the electrical connector. The inspection sensors 220 may be image sensors configured to analyze digital images or other types of images.

[0057] The control module 264 includes one or more electrical components such as a processor, IC components, memory devices, CMOS sensors, a field-programmable gate array (FPGA), and a digital signal processor (DSP). For example, the control module 264 includes one or more processors 265 for processing inspection data. In exemplary embodiments, the control module 264 may be programmable. For example, the control module 264 may receive wireless update signals to update, for example, analysis software or algorithms. During operation, the control module 264 may execute a program to process and / or analyze inspection data, for example, for health assessment. For example, the control module 264 runs a program stored in one or more memories of the processor 265. Data analysis may be used to enable / deny connection or operation of electrical connectors, for routine maintenance, or to assess efficiency (e.g., power conversion efficiency for predicting charging time based on the use of electrical connector 10).

[0058] Processor 265 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.

[0059] In exemplary embodiments, various components such as memory and processor 265 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, peripheral bus, accelerated graphics port, and a processor or local bus using any of the various bus structures.

[0060] The control module 264 may include various computer system-readable media. Such media may be any available media accessible by the control module 264, 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 264 may further include other removable / non-removable volatile / non-volatile computer system storage media. As just one example, a storage system for performing read and write operations on 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.

[0061] 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.

[0062] The control module 264 may also communicate with one or more external devices, such as via the communication module 266 of the control module 264, for data sharing and / or analysis by a remote inspection device. In an exemplary embodiment, the communication module 266 communicates with the communication module 166 of the connector health monitoring device 100. For example, the communication module 266 may receive inspection data from the connector health monitoring device 100 and / or transmit health evaluation output or other data to the connector health monitoring device 100. The communication module 266 may also communicate with the electrical connector 10 or a system incorporating the electrical connector 10 (e.g., a charging station or an electric vehicle). The communication module 266 may communicate with the user via a mobile device (e.g., a mobile phone app or a vehicle display system). In various embodiments, the communication module 266 is configured to communicate wirelessly via Bluetooth®, Wi-Fi®, cellular, or other wireless protocols. Health data or other signals may be shared with the electrical connector or a 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 the user to interact with the system, such as a keyboard, pointing device, or display; one or more mobile devices (e.g., a mobile phone or mobile inspection unit); one or more devices associated with the electrical connector 10 (e.g., 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 or modem). Such communication may be performed via input / output (I / O) interfaces. Furthermore, the control module 264 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.

[0063] Computer software, including instructions or code for performing the methods of 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, 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, etc. 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. As an example, but is 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.

[0064] In an exemplary embodiment, the inspection sensor 220 associated with the control module 264 includes a force measuring sensor 230 for detecting the mating force with the detachable connector interface 22. The force measuring sensor 230 may detect, for example, FOD by detecting the compressive force of the pogo pin 118.

[0065] In an exemplary embodiment, the inspection sensor 220 associated with the control module 264 includes an electrical resistance measuring sensor 232 for detecting the electrical resistance with a separable connector interface 22, such as an inspectable contact. The electrical resistance measuring sensor 232 detects the electrical resistance between the pogo pin 118 and the inspectable contact.

[0066] In an exemplary embodiment, the inspection sensor 220 associated with the control module 264 includes a position measuring sensor 234 for detecting the mating position between the inspection probe 110 and the detachable connector interface 22. The position measuring sensor 234 may include at least one of an optical sensor, a laser measuring sensor, and a proximity sensor for detecting the mating position between the inspection probe 110 and the detachable connector interface 22. For example, proximity detection may communicate with the electrical connector 10 and / or a system associated with the electrical connector 10 (e.g., an electric vehicle charging station) to confirm the presence of the inspection device. The position measuring sensor 234 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 234 may also detect the length of the pogo pin 118 and / or the amount of compression of the pogo pin 118.

[0067] In an exemplary embodiment, the health assessment device 200 includes a camera 280 for photographing the electrical connector 10. The camera 280 is operably coupled to an analysis module 260, such as a control module 264. For example, images from the camera may be transmitted to the analysis module 260. The images from the camera 280 may be analyzed by the analysis module 260 to provide a health assessment of the electrical connector 10. For example, the images may be analyzed to identify the location of inspectable contacts relative to each other or to the connector housing. The images may be analyzed to determine the size of the inspectable contacts and / or the spacing between the inspectable contacts and the connector housing. The images may be analyzed to identify FODs in the mating interface. The images may be analyzed to identify damage, wear, or other problems caused by the inspectable contacts. The 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.

[0068] The analysis module 260 may analyze images using an image processing module and / or image processing algorithms 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. Images may be analyzed by the analysis module 260 or by a remote device. For example, images may be sent to another device and / or the cloud for offline analysis. The analysis module 260 or other devices used for analysis may include an AI learning module to improve or enhance image analysis based on the images.

[0069] When in use, the camera 280 is positioned to show 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.

[0070] In an exemplary embodiment, the integrity assessment device 200 includes an illumination element 282 held by a device housing 240. The illumination element 282 is configured to illuminate the electrical connector 10, such as the contacts, housing, or other components of the electrical connector 10 that can be inspected. The illumination element 282 is used to improve image acquisition by the camera 280. The illumination element 282 may measure ambient light and determine its intensity, color, or other illumination characteristics to improve image acquisition by the camera 280.

[0071] In exemplary embodiments, the health assessment device 200 integrates various detection or measurement techniques, such as resistance measurement and force measurement. Additionally or alternatively, the health assessment device 200 may perform health assessment using inspection data in the form of images from the camera 280 of the health assessment device 200. Alternatively, the camera 280 may be integrated with the connector health monitoring device 100 to photograph the electrical connector 10 during the inspection process. The health assessment device 200 offers several advantages. By combining FOD detection with resistance measurement, force measurement, and / or image processing, the health assessment device 200 can improve accuracy and provide a more comprehensive analysis of the interface condition. The design's versatility allows for both FOD-only applications and combined FOD / electrical measurement applications. The system's customizability enables adaptation to various interface geometries. The integrity assessment device 200 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 integrity assessment device 200 performs integrity assessments on separable interfaces and provides a significant improvement over existing methods by performing multifaceted analysis of interface conditions. Integrating resistance and force measurement capabilities alongside FOD detection enables more accurate and reliable identification of potential problems in critical connections. In various embodiments, image analysis may be additionally used to further improve the health assessment analysis.

[0072] The health assessment device 200 can be a separate handheld device. In various other embodiments, the health assessment device 200 can be integrated into the electrical connector 10, or into a system component associated with the electrical connector 10, such as a charging inlet or charging plug or an assembly robot. The health assessment device 200 can be integrated into various types of connector systems, but is not limited to use in electric vehicle charging. The health assessment device 200 may be used for detection in OEM assembly, or by maintenance technicians or Tier I / II suppliers. The health assessment device 200 can be used for FOD detection by users, such as via a mobile phone or other mobile device interface. In various embodiments, the integrity assessment device 200 may be incorporated into an assembly robot. For example, the integrity assessment device 200 may be incorporated into a robot end effector that can inspect interfaces during assembly. For example, the robot end effector may check for FOD before assembling connectors in a highly contaminated environment.

[0073] Figure 8 shows a connector health monitoring system 70 according to an exemplary embodiment. The connector health monitoring system 70 includes a connector health monitoring device 100 and a health evaluation device 200. The monitoring device 100 is used to monitor the health of the charging terminals used to charge the electric vehicle 80. The connector health monitoring system 70 measures the health of the charging interface when the vehicle 80 is connected to the charging station 20.

[0074] The connector health monitoring system 70 may be used to detect the presence of foreign objects in the charging interface before and / or during charging. The connector health monitoring system 70 may be used to evaluate the health of the charging terminals in the charging interface before and / or during charging. The connector health monitoring system 70 may provide signals to allow or deny charging based on the measured health of its particular separable interface and / or based on FOD detection. The connector health monitoring system 70 mitigates dissatisfaction due to low charging speed, potential harmful user intervention (shaking the charging plug to increase charging speed), or damage to the inlet and charging plug due to poor interface health.

[0075] Components of the connector health monitoring system 70 may be incorporated into the electric vehicle 80 and / or the charging station 20 for charging the electric vehicle to monitor the health of charging components, for example, to control charging operations. For example, the connector health monitoring device 100 may be incorporated into the electric vehicle 80 and / or the charging station 20. Additionally or alternatively, a health assessment device 200 may be incorporated into the electric vehicle 80 and / or the charging station 20. The connector health monitoring system 70 may permit 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 system 70 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 system 70 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.

[0076] 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 incorporated into the charging terminal 90.

[0077] 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.

[0078] In various embodiments, the connector health monitoring device 100 may be part of the electric vehicle 80. For example, the connector health monitoring device 100 may be part of the charging inlet 82. The connector health monitoring device 100 may be part of the battery system. As an addition or alternative, the health evaluation device 200 may be part of the electric vehicle 80. For example, the health evaluation device 200 may be part of the charging inlet 82. The health evaluation device 200 may be part of the battery system. In various other embodiments, the connector health monitoring device 100 may be part of the charging station 20. For example, the connector health monitoring device 100 may be part of the charging plug 40. Alternatively, the health evaluation device 200 may be part of the charging station 20. For example, the health evaluation device 200 may be part of the charging plug 40.

[0079] The connector health monitoring system 70 may control the power supply from the charging station 20 to the charging inlet 82. For example, the connector health monitoring system 70 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 the presence of foreign matter, the charging operation may be refused. In an exemplary embodiment, the connector health monitoring system 70 allows individual consumers, vehicle owners, charging station maintenance operators or other individuals to assess the health of the charging plug 40 and determine whether maintenance and / or replacement of the charging plug 40 or its components is necessary. The connector health monitoring system 70 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 system 70 compares the measured resistance to a known connection database ranging from good to bad and provides the user with an index of the health of a particular charging terminal 50 to determine whether the charging terminal 50 needs maintenance or replacement. The connector health monitoring system 70 may also 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.

[0080] The embodiments described herein may have safety mechanisms incorporated into the design. For example, the product may be designed to prevent high voltage in the tester (e.g., connector health monitoring device 100). For example, the connector health monitoring device 100 may have certain components removed to limit the flow of high voltage in the interface. For example, by removing the control pilot terminal and / or proximity pilot terminal and / or protective earth terminal from the mating interface, the tester may not be recognized as a vehicle during inspection, and therefore high voltage charging may not occur.

Claims

1. A connector health monitoring system (70) for evaluating the health of an electrical connector (10), wherein the connector health monitoring system is A connector health monitoring device (100) comprising a device housing (140) and an inspection probe (110) held by the device housing, wherein the device housing includes a mating end (112) configured to mate with the electrical connector, the inspection probe is positioned at the mating end to mate with an inspectable contact of the electrical connector to generate inspection data, and the connector health monitoring device includes a communication module (166) configured to transmit the inspection data. A health evaluation device (200) is communicatively coupled to the connector health monitoring device, wherein the health evaluation device includes a communication module configured to receive the inspection data from the communication module of the connector health monitoring device, and the health evaluation device includes an analysis module (260) including a processor (165) for performing a health evaluation of the electrical connector based on the inspection data. A connector health monitoring system (70) is provided.

2. The connector health monitoring device (100) according to claim 1, wherein the health evaluation device (200) is separate from and independent of the connector health monitoring device.

3. The connector health monitoring device (100) according to claim 1, wherein the inspection data is transmitted to the health evaluation device (200) by the connector health monitoring device before processing the inspection data.

4. The connector health monitoring device (100) according to claim 1, comprising one or more processors (165) for processing the inspection data, wherein the processed inspection data is transmitted to the health evaluation device (200) for analysis.

5. The connector health monitoring device (100) according to claim 1, wherein the health evaluation device (200) is a handheld mobile device.

6. The connector health monitoring device (100) according to claim 1, wherein the health evaluation device (200) is a system component associated with the electrical connector (10).

7. The connector health monitoring device (100) according to claim 1, wherein the electrical connector (10) is a charging plug (40) of a charging station (20), and the health evaluation device (200) is integrated with the charging station.

8. The connector health monitoring device (100) according to claim 1, further comprising an assembly robot having a robot arm and an end effector at the end of the robot arm, wherein the connector health monitoring device (200) is held by the end effector, and the health evaluation device is integrated with the control module (164) of the assembly robot.

9. The connector health monitoring device (100) according to claim 1, wherein the health evaluation device (200) generates an output based on the health evaluation.

10. The connector health monitoring device (100) according to claim 1, wherein the analysis module (260) of the health evaluation device (200) performs predictive analysis of the operating characteristics of the electrical connector (10).

11. The connector health monitoring device (100) according to claim 1, wherein the communication module (166) of the connector health monitoring device is configured to communicate with the health evaluation device (200) located near the connector health monitoring device via short-range wireless communication.

12. The connector health monitoring device (100) according to claim 1, wherein the communication module (166) of the connector health monitoring device is configured to communicate with the health evaluation device (200) via cellular wireless communication over a cellular network.

13. The connector health monitoring device (100) according to claim 1, wherein the analysis module (260) includes a neural network for machine learning based on the inspection data.

14. The connector health monitoring device (100) according to claim 1, further comprising a camera (280) for photographing the mating interface (102) of the electrical connector (10), wherein the camera generates an image, and the analysis module (260) performs the health assessment based on the inspection data and the image.

15. The connector health monitoring device (100) according to claim 1, wherein the connector health monitoring device includes a position sensor (234) for determining the position of the connector health monitoring device relative to the electrical connector (10).

16. The connector health monitoring device (100) according to claim 1, further comprising a positioning device (167) configured to generate a positioning tag, wherein the positioning device is associated with either the connector health monitoring device or the health evaluation device (200), and the positioning tag is associated with the health evaluation.

17. The connector health monitoring device (100) according to claim 1, wherein the analysis module (260) receives a signal wirelessly to perform a health assessment and updates the analysis module.

18. The connector health monitoring device (100) according to claim 1, wherein the inspection probe (110) is configured to inspect at least one of the force measurement, size measurement, and electrical characteristics of the inspectable contact.

19. 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).

20. 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 dielectric housing, the dielectric housing includes a second mating end located on the second side of the dielectric housing, the connector health monitoring device further comprises a second inspection probe (110) located on the second mating end, the first mating end has a first layout for mating with a first type of electrical connector (16), and the second mating end has a second layout for mating with a second type of electrical connector (18).

21. The connector health monitoring device (100) according to claim 1, further comprising a user interface (290) coupled to the device housing (140).

22. The connector health monitoring device (100) according to claim 1, wherein the analysis module (260) 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.

23. The connector health monitoring device (100) according to claim 1, wherein the inspection probe (110) includes a pogo pin (218) configured to interface with the inspectable contact for inspecting at least one of the mating force with the inspectable contact and the electrical resistance with the inspectable contact.

24. 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.

25. The connector health monitoring device (100) according to claim 1, wherein the inspection probe (110) includes a low-wear layer on the mating interface (202) to improve wear resistance.

26. A connector health monitoring system (70) for evaluating the health of a charging connector for an electric vehicle (80), wherein the connector health monitoring system is A connector health monitoring device (100) comprising a device housing (140) and an inspection probe (110) held by the device housing, wherein the device housing includes a mating end (112) configured to mate with the charging connector, the inspection probe is positioned at the mating end to mate with the charging contacts of the charging connector to generate inspection data, and the connector health monitoring device includes a communication module (166) configured to transmit the inspection data. A health evaluation device (200) is communicatively coupled to the connector health monitoring device, wherein the health evaluation device includes a communication module configured to receive the inspection data from the communication module of the connector health monitoring device, and the health evaluation device includes an analysis module (260) including a processor (165) for performing a health evaluation of the electrical connector (10) based on the inspection data. A connector health monitoring system (70) is provided.

27. A method for monitoring the integrity of a separable connector interface (22) of an electrical connector (10), wherein the method is: To provide a connector health monitoring device (100) including a device housing (140) and an inspection probe (110) held by the device housing, wherein the device housing includes a mating end (112) configured to mate with the electrical connector, the inspection probe is positioned on the mating end, and the connector health monitoring device includes a communication module (166). The inspection probe is mated with the inspectable contacts of the electrical connector in the detachable connector interface (22), The inspection probe measures the integrity evaluation characteristics of the inspectable contact and generates inspection data. The connector health monitoring device transmits the inspection data to the health evaluation device (200), Based on the measured integrity assessment characteristics, the integrity assessment device generates an integrity assessment of the inspectable contact. Methods that include...

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