Connector that can eliminate the boost mechanism

Abstract

Connectors equipped with a power-boosting mechanism have been difficult to control, particularly with lever operation, making it difficult to mechanize the mating process. This invention makes it possible to mechanize the connector mating process in the vehicle assembly process, thereby eliminating the need for a power-boosting mechanism. [Solution] The power-boosting mechanism is eliminated, simplifying the connector mating process. It also enables connector mating and unmating to be performed using general-purpose tools and parts in later processes, such as in vehicle assembly. This allows for the mechanization of connector mating work using automated machines and motion-assistance devices in the vehicle assembly process, eliminating the power-boosting mechanism. It also provides an environment that improves the reliability of connector connections.

Description

[Technical Field]

[0001] The present invention relates to a connector that can dispense with a force-boosting mechanism. [Background technology]

[0002] Conventional connectors have a structure equipped with a force-boosting mechanism to reduce the mating force, which makes mating and unmating the connector easier (see, for example, Patent Document 1: JP 2002-359028).

[0003] However, there is also a structure that does away with the power-boosting mechanism and uses a general-purpose tool (screwdriver) to mate and detach the connector. This structure does not require a specific dedicated tool, but rather allows for the use of a general-purpose tool, which increases work flexibility and reduces the number of parts and weight (see, for example, Patent Document 2: JP 2012-134008).

[0004] There are also structures that do away with the power-boosting mechanism and use general-purpose parts (bolts and nuts) to mate and detach connectors. This structure does not require specialized parts or tools, and instead allows for the use of general-purpose parts and tools, which increases work flexibility and reduces the number of parts and weight (see, for example, Patent Document 3: JP 9-245884). [Prior art documents] [Patent documents]

[0005] [Patent Document 6] Japanese Patent Application Publication No. 10-55855 Summary of the Invention [Problem to be solved by the invention]

[0006] The mating process of connectors equipped with conventional force-boosting mechanisms requires a series of steps to hold the connector, correct its position, temporarily set it in the mating connector, and then operate a lever to complete the mating. As a result, mechanizing the mating process is not cost-effective and cannot be easily implemented.

[0007] Furthermore, multi-pole connectors that require a boosting mechanism generally require a wire protection cover to be attached to prevent damage to the wires when passing through holes in the vehicle panel during assembly, and to guide the direction of the wire routing. When mating a connector equipped with a power-boosting mechanism, the pushing operation is performed by operating the power-boosting mechanism part, so even if a wire protection cover is attached, there was an issue of not being able to secure enough space to push the connector when mating it automatically.

[0008] Connectors that do away with the force-boosting mechanism and can be mated and unmated with a general-purpose tool (screwdriver) have an opening at the rear end of the housing, and a protrusion protruding from the opening is operated with the general-purpose tool to mating and unmating. This creates a problem when pushing the rear end of the housing in with an automatic machine to mate, as there is limited space available for pushing in.

[0009] Furthermore, if a wire protection cover is attached, it must be removed when disconnecting and reconnecting the connector using general-purpose tools in the subsequent process, which poses a risk of damaging the wire protection cover depending on the worker's level of skill.

[0010] Furthermore, when this structure is applied to a waterproof connector, it is necessary to prevent water from entering the connector through the opening at the rear end of the housing, which poses the issue of increased costs and product weight.

[0011] Connectors that do away with a separate power-boosting mechanism and use generic parts (bolts and nuts) for mating and unmating are also designed to be used during the vehicle assembly process. Therefore, nuts must be pre-assembled onto each housing. This increases the number of parts and the amount of work required to assemble the nuts, which creates the problem of increased costs and product weight.

[0012] Additionally, bolts for mating the connectors must be prepared during the vehicle assembly process, and then removed after mating. This increases the amount of work required in the vehicle assembly process compared to connectors that come with pre-assembled bolts and nuts, which can be completed simply by tightening the bolts.

[0013] Furthermore, if the connector needs to be removed later in the vehicle assembly process (such as at a repair shop), the bolt thread specifications must match those of the nuts already attached to the housing.If a bolt with a different pitch is accidentally tightened, the threads may be damaged, and if the nut is damaged, it cannot be replaced, which creates the problem of the connector becoming unable to be removed.

[0014] This invention simplifies the mating process by eliminating the connector's force-boosting mechanism. It also makes it possible to mate and detach the connector using general-purpose tools and parts, even when the wire protection cover that secures the pressing part is attached. Furthermore, it avoids the increase in costs and product weight due to an increase in the number of parts, as well as reduced work efficiency during the vehicle assembly process. These efforts aim to enable the mechanization of mating operations using automated machines and motion-assistance devices during the vehicle assembly process, eliminating the need for force-boosting mechanisms and providing an environment that improves the reliability of connector connections. [Means for solving the problem]

[0015] In order to achieve the above object, the present invention provides a pair of connectors to be mated and connected by providing an opening in the receiving wall of the mating housing of one connector and providing a support portion when the mating housing is pushed out. The housing of the other connector is provided with a push-out section that faces the support section used when pushing out and the mating direction, making it possible to mate and detach the connectors with a general-purpose tool even if the connector's force-boosting mechanism is eliminated.

[0016] As a means of solving the second problem, a support portion is provided on the housing of one of the connectors when the mating housing is pulled in, and a pulling portion is provided on the housing of the other connector that faces the support portion when pulling in in the mating direction, making it possible to mate and detach the connectors with a general-purpose tool even if the connector's force-boosting mechanism is eliminated.

[0017] As a third means for solving the problem, through holes are provided in the support and push-out portions when pushing out and in the support and pull-in portions when pulling in, and this configuration eliminates the openings, making it possible to mate and detach the connector using general-purpose tools and / or general-purpose parts even if the connector's force-boosting mechanism is eliminated.

[0018] Furthermore, as a fourth solution to the problem, a pressing portion is provided on one of the connectors to be used when mating the other connector, ensuring a stable pressing surface when mating the connectors using an automated machine or motion assistance device, thereby making the mating process more efficient. [Effects of the Invention]

[0019] The first solution to the problem described above makes it possible to mate and detach connectors using general-purpose tools in post-vehicle assembly processes and assembly processes that do not have mechanized equipment, even if the connector's force-boosting mechanism is eliminated. Furthermore, the connector can be connected and disconnected in the same way even with the wire protection cover attached. In addition, the elimination of the power-boosting mechanism simplifies the connector mating process. These features enable the mechanization of the mating process of non-waterproof and waterproof connectors using automatic machines and motion-assistance devices, eliminating the need for a power-boosting mechanism.

[0020] Furthermore, with the second solution to the problem, just like the first solution, even if the connector's force-boosting mechanism is eliminated in later processes in the vehicle assembly process, the connector can still be mated and detached using the same general-purpose tool. As with the first solution, this makes it possible to mechanize the mating process of non-waterproof and waterproof connectors, eliminating the need for a boosting mechanism.

[0021] Furthermore, the third solution to the problem, like the first solution to the problem, makes it possible to mate and detach the connector using general-purpose tools and / or general-purpose parts, even if the connector's force-boosting mechanism is eliminated in later processes of the vehicle assembly process. As with the first solution, this makes it possible to mechanize the mating process of non-waterproof and waterproof connectors, eliminating the need for a boosting mechanism.

[0022] Furthermore, the fourth solution ensures a stable pressing surface when mating connectors with automatic machines and motion assistance devices, reducing tilt and loss of pressing force against the mating housing. This will stabilize work using automated machines and motion assistance devices, and in particular simplify the control of automated machines, contributing to the mechanization of mating work.

[0023] Furthermore, during the vehicle assembly process, workers will temporarily set one connector to the other connector, and then an automated machine will simply push the other connector into place along the housing of the other connector. This simplifies the control of the automated machine and reduces the need to replace end effectors. In addition, the efficiency of the automated machine is improved by allowing multiple tasks to be performed by a single machine. These features contribute to the mechanization of connector mating work.

[0024] As the mating process becomes more mechanized, the correct mating state can be guaranteed by detecting the mating state of connectors using position sensors and force sensors. This prevents poor circuit continuity due to connector disconnection, improving the reliability of the connector connection. Furthermore, the same guarantee can be achieved by attaching the sensor together with the motion assistance device to a location where it will not get in the way, such as the wrist of the worker, and detecting the mating status of the connector.

[0025] Since the connector is not assumed to be fitted with bolts and nuts during the vehicle assembly process, the increase in cost and product weight that would occur by pre-assembling nuts to the housing can be avoided. It also prevents the reduction in work efficiency caused by tasks such as removing bolts after mating connectors during the vehicle assembly process.

[0026] In processes such as the post-vehicle assembly process, connectors can be mated and detached using general-purpose tools and parts with the wire protection cover attached. This eliminates the need to remove the wire protection cover, eliminating the risk of damaging the cover.

[0027] By eliminating the booster mechanism, the booster mechanism part (see lever 130 in Figure 7 of Patent Document 1), which had a nesting structure that hindered separation of the connector when the vehicle was dismantled, is no longer required, making it easier to separate the connector and improving the work of removing the wire harness from the vehicle body using heavy machinery (Nipla). This is expected to improve the efficiency of vehicle dismantling work and contribute to easier dismantling designs.

[0028] In addition, the connectors can now be easily separated, reducing damage to plastic parts and enabling material identification by material markings.Furthermore, the absence of a multiplying mechanism, which often uses reinforced plastic materials and housings with different colors, reduces the number of parts, material types, and materials with different colors that need to be collected, improving the workability of collection and sorting. This is expected to improve recyclability and horizontal recycling rates, and contribute to resource conservation and environmental protection by utilizing resources and reducing CO2 emissions. [Brief explanation of the drawings]

[0029] [Figure 1] 1A and 1B are explanatory views of a mechanized mating operation according to an embodiment of the present invention, showing the start of temporary setting and the start of final locking, respectively. [Figure 2] 1 is an explanatory diagram of the general-purpose tool type operation of the first embodiment, (a) removal using a screwdriver, (b) with a mating cover using pliers, and (c) without the cover. [Figure 3] An explanatory diagram of the connector's operation. (a) Disconnection begins, (b) Disconnection complete. [Figure 4] 10A and 10B are explanatory views of a general-purpose tool type of the second embodiment, (a) connector mating operation, (b) component parts (plan view), and (c) component parts (bottom view). [Figure 5] An explanatory diagram of the connector's operation. (a) Starting mating, (b) Completed mating. [Figure 6] 3A and 3B are explanatory diagrams of general-purpose parts according to Example 3-1, in which (a) is the target general-purpose part, and (b) is a component part. [Figure 7] An explanatory diagram of the connector's operation. (a) Preparation for disconnection, (b) Start of disconnection, (c) Disconnection completed. [Figure 8] An explanatory diagram of the connector's operation: (a) Preparation for mating, (b) Starting mating, (c) Completed mating. [Figure 9] 10A and 10B are explanatory views of the general-purpose tool type operation of Example 3-2, (a) removal completed, (b) cross-sectional view of the same. [Figure 10] 10A and 10B are explanatory diagrams illustrating an example of application of the embodiment 3-3 to a vehicle body panel locking connector. (a) Temporary setting start, (b) Main locking start, (c) Assembly completion. [Figure 11] FIG. 10 is an explanatory diagram of an application example of the fourth embodiment to a waterproof connector, (a) removal operation, (b) component configuration. [Figure 12] Cross-sectional view of the connector. (a) Lock arm operation flow diagram (detail B) Mating start, (b) Mating midway, (c) Mating completion. [Figure 13] 10 is an explanatory diagram of the fifth embodiment, (a) component parts, (b) applicable general-purpose parts, (c) mating completion, (d) mating start. [Figure 14] Conventional low insertion connectors. (a) Patent Document 1, (b) Patent Document 2, (c) Patent Document 3, (d) Patent Document 4. DETAILED DESCRIPTION OF THE INVENTION

[0030] An example of mechanization of connector mating work in the vehicle assembly process using an articulated robot is explained based on Figures 1 to 5.

[0031] FIG. 1(a) shows a state in which a worker 70 holds the other connector 20, corrects its posture, and then temporarily sets it on the other connector 10. 1(b) shows the state where the articulated robot 80 presses the pressing part 51 of the wire protection cover 50 to push the other connector 20, which has been temporarily set into one connector 10, into the connector 10, completing the connector mating work. Note that this work can also be performed by a worker wearing a movement assist device.

[0032] When worker 70 temporarily sets one connector 20 to the other connector 10, he or she pushes the other connector 20 further after the male terminals 30 and female terminals 40 have made initial contact (see Figure 5a), so that the contact load between the terminals will not cause connector 20 to come out of the temporary set state. If there is a concern that the connector may come loose before the connector mating work is completed due to the location and conditions of the connector assembly in the vehicle, additional measures can be taken, such as providing a temporary locking structure in the mating housing accommodating wall 10h to increase the holding force (see protrusion 40 and window 39 in paragraph 0028 of Patent Document 5).

[0033] The articulated robot 80 performs the mating work by programming the standby position for starting the pushing operation in advance, and then analyzes the image of the pressing part 51 on the rear end face of the wire protection cover captured by the camera 83 with an image processing system, recognizing the pressing part and then starting the pushing operation. During the pushing operation, the acceleration sensor 84 and force sensor 82 detect the mating state of the connector, and the robot pushes it to the specified position.

[0034] Furthermore, because the articulated robot 80 works in cooperation with the worker 70, it is necessary to strictly adhere to the safety requirements of industrial robot regulations and ensure safety based on risk assessment, including the setting of the push-in load required for connector mating. In addition to installing an emergency stop device as a safety measure, risks can be reduced and safety can be increased by designing a process in which the worker and robot do not work in the same space.

[0035] As an example, a parallel opening / closing gripper 81 (end effector) for gripping work is attached to the tip of the robot arm of the articulated robot 80. If there is no wire protection cover attached, the left and right opening / closing claws 81a will press the wire protection cover intrusion prevention protrusions (25a, four locations, b and c in Figure 4) of the other connector 20. The cover intrusion prevention protrusions 25a and removal prevention protrusions 25b are set in a layout that increases the versatility of the left and right opening / closing claws.

[0036] If the electric wire protection cover 50 is attached, the parallel opening / closing type gripper base 81b holding the opening / closing claws presses the pressing part 51 on the rear end surface of the cover.

[0037] [Wire protection cover] The wire protection cover 50 is assembled by sliding it onto the housing in a direction perpendicular to the connector mating direction (see a and b in Figure 4). The cover's anti-slip projection 55b slides between the housing's anti-insertion projection 25a and anti-slip projection 25b. The cover's slide lock projection 55c is displaced outward due to the taper and slit 55d of the lock projection, riding onto projection 25b, and then returns to its original position after passing projection 25b, thereby locking into slide lock portion 25c and preventing it from coming off in the sliding direction.

[0038] When removing the wire protection cover 50, a precision screwdriver is inserted into the jig insertion portion 55e of the cover, and the slide locking protrusions 55c are displaced outward to release the lock, allowing the cover to slide and be removed.

[0039] When mating the connectors, pressing the pressing portion 51 on the rear end face of the wire protection cover causes the insertion prevention protrusion 25a of the housing to come into contact with the insertion prevention portion 55a of the cover, pushing in the other connector 20.

[0040] Furthermore, when the electric wire is pulled by an external force, the anti-slip projection 55b of the electric wire protection cover abuts against the anti-slip projection 25b of the housing, preventing the electric wire protection cover 50 from coming off the housing 20h.

[0041] This wire protection cover 50 uses a U-shaped cross section (see Figure 4 c) with a wide flat surface for the pressing part 51, ensuring a stable pressing surface when mating the connector with an automatic machine. When this cross section shape is used, the U-shape may collapse inward due to post-molding shrinkage when the part is molded (collapse in the direction of arrow a in Figure 4 c), which can reduce the ease of assembly into the housing.

[0042] In this example, the wire protection cover is designed to take into account inward tilting, so when it is assembled to the housing, the corners of the housing (25f) pick up the end (55f) and correct the tilting. This allows for a U-shaped cross section, ensuring good assembly to the housing and a stable pressing surface. If necessary, the end (55f) can be chamfered and the corners (25f) can have a larger radius.

[0043] One way to prevent inward collapse is to make the corners of the U-shaped tube, which have a slower cooling rate, unevenly thickened to match the cooling rate of the other parts, thereby making the shrinkage uniform and preventing collapse.In this case, the corners will have a thinner wall due to the uneven thickness, which may cause deformation when the pressing part is pressed, which may damage the wire.

[0044] Another method to prevent tipping is to change the U-shape to a U-shape or V-shape (see Figure 1 of Patent Document 6), but in either case, the flat surface of the pressing part cannot be made wider, so the automatic machine needs to control the tilt correction relative to the mating direction, which does not contribute much to making mechanization possible.

[0045] In contrast to the slide-type locking structure employed in this embodiment, there is also a structure in which the locking portion of the wire protection cover is spread outward before being assembled to the housing (see 22 in Figure 1 of Patent Document 7). With this structure, there is a risk of the wires being pinched between the cover and the housing when assembling the cover to the housing. Furthermore, when the wires are pulled by an external force, the locking arm 22 (the symbol in the reference publication) on the cover side tends to spread outward. If an opening prevention protrusion (315g in Figure 11b of Example 4 of the present invention) is provided, the locking arm 22 and the opening prevention protrusion will interfere with each other, making it impossible to assemble the cover. Therefore, if the force-boosting mechanism can be eliminated and assembly of the wire protection cover by sliding becomes easier, the slide-type locking structure is recommended.

[0046] [Connector mating guarantee] When detecting the mating state of the connector using a sensor, a mating waveform of the connector is generated from the displacement amount by the acceleration sensor 84 and the reaction force by the force sensor 82, and the mating state can be confirmed based on this mating waveform. At that time, the confirmation results are entered into a quality control system and saved in a database (see S24 in Figure 6 of Patent Document 8).

[0047] Since the actuator of the articulated robot 80 in this embodiment is assumed to be an electric type, the amount of displacement detected by the acceleration sensor is calculated based on the output information from the angular acceleration sensor (encoder) built into the servo motor of each joint.

[0048] The correct mating state is determined when the housings (walls 16 and 26 in Figure 5a) butt against each other (see Figure 5b) after the reaction force peaks in the connector mating waveform, and the displacement (stroke) becomes almost zero and the reaction force (load) rises sharply (see the graph in Figure 8 of Patent Document 9). After this, the pushing should be stopped immediately to complete the operation.

[0049] Furthermore, a sudden increase in reaction force after the reaction force peak can also occur if a foreign object gets inside the mating housing wall 10h of one connector 10 and becomes pinched between it and the mating housing 20h, so we recommend managing the displacement between the reaction force peak and the sudden increase in reaction force based on the design value and / or using the lock arm mating assurance method described below. This will prevent poor circuit continuity due to connector disconnection and improve the reliability of the connector connection.

[0050] Furthermore, we suggest that the reaction force value also be managed to check the terminal contact status. In this case, we believe that it is ideal to manage the actual terminal contact load value in addition to the number of circuits. In particular, with multi-pole connectors, handling in the wire harness state can lead to deformation of the male terminal tab 31a (see a in Figure 3) and the female terminal tongue portion 41a (see the same figure). These factors can lead to contact between terminals in an irregular state or insufficient contact load, which can increase circuit resistance, so managing reaction force values ​​can be expected to help prevent these from occurring.

[0051] This concludes the explanation of an example in which the connector mating process in the vehicle assembly process has been mechanized by eliminating the power-boosting mechanism to simplify the connector mating process and dividing the entire mating process between the worker and the automated machine.

[0052] Next, we will explain examples of connector mating and unmating in processes downstream of vehicle assembly and assembly processes without mechanized equipment, following the elimination of the power-boosting mechanism.

[0053] Example 1: An example of connector disconnection and connection using general-purpose tools (such as a screwdriver and pliers) is explained based on Figures 2 and 3. Note that, like the other examples, the state in which the terminals are assembled into the housing is omitted.

[0054] In a pair of connectors to be mated and connected, an opening 10a is provided in the mating housing accommodating wall 10h of one connector 10, and a support portion 13 is provided when the mating housing 20h is pushed out. The housing 20h of the other connector 20 is provided with a push-out portion 23 that faces the push-out support portion 13 in the mating direction, and the connectors can be removed by a multiplying mechanism that uses a general-purpose tool 60 as a lever.

[0055] Figure 3(a) shows the connectors mated, with the tip 61 of a general-purpose tool 60 (flathead screwdriver) inserted into the gap between the support part 13 and the push-out part 23 to begin disengagement.

[0056] Because support part 13 serves as a fulcrum when pushing out, wall thickness 13t is set to a strength that takes into account the necessary safety factor depending on the usage situation when load F1 (= F2·L2 / L1) applied to force point 62 (see a in Figure 2) of general-purpose tool 60 by the leverage ratio is added to connector removal force F2. L1 is the distance from the force point to support part 13b when pushing out, and L2 is the distance from general-purpose tool tip 61a to 13b.

[0057] The push-out portion 23 has a pick-up 23a for inserting the general-purpose tool, a surface 23b that ensures a gap for inserting the tip of the general-purpose tool, and a stopper 23c that prevents the general-purpose tool from being inserted too far in a position that ensures the required leverage ratio, and the wall thickness 23t is set to a strength that takes into account the above-mentioned safety factor when a connector removal force F2 is applied.

[0058] Figure 3(b) shows the state in which the other connector 20 is pushed out by operating the general-purpose tool 60, allowing the worker to remove the connector. The general-purpose tool is operated until the operating force decreases. This causes the tapered end 31b at the tip of the male terminal tab 31a to be pushed out to a position where it has passed the contact portion 41b of the female terminal tongue portion 41a, causing the tongue portion, which had been displaced due to the thickness of the male terminal tab, to return to its original position, reducing the contact load and enabling the above-mentioned removal.

[0059] When inserting tip 61 of general-purpose tool 60 into the gap between support portion 13 and push-out portion 23 during push-out, tip 61 is inserted until it hits stopper 23c, and then using support portion 13b as a fulcrum and the general-purpose tool as a lever, tip 61a presses push-out surface 23b to detach the other connector 20. At this time, the general-purpose tool shifts from fulcrum portion 13b, preventing tip 61a from coming off push-out surface 23b. Furthermore, depending on the load required to remove the connector and the amount of displacement to push out connector 20, the flathead screwdriver can be rotated in the radial direction in the same way as when tightening a screw, and when tip 61 is cross-sectioned in a direction perpendicular to the axis of rotation, the opposing corners become the fulcrum and point of application, and the connector can be removed using the principle of leverage.

[0060] The mating method is explained based on Figure 2 (b) and (c). To begin mating the connectors, the worker pushes the other connector 20 into the position just before the peak contact load of the terminals occurs. At this time, the tapered end 31b of the male terminal is pushed into the position just before it passes the contact part 41b of the female terminal (see Figure 5(a)). In this state, the end faces of both housings are clamped with a general-purpose tool 65 (pliers) and mated (see Figure 5 of Patent Document 10). In this case, for connectors that do not have a wire protection cover, the extrusion support 13 ensures space for clamping the terminal housings of the empty circuits together in the area where there is no terminal housing (see 21 in Figure 4b). Also, care must be taken when selecting tools to avoid damaging the wires. Instead of pliers, it is also possible to use a rubber hammer or similar tool to press the rear end face of the wire protection cover to fit it. In this case, it is necessary to provide reinforcing ribs on the wire protection cover to ensure strength and to widen the pressing surface to distribute stress. L-shaped clamps, F-shaped vises, slide hammers, etc. can also be used instead.

[0061] Example 2: An example of mating a connector using a general-purpose tool (flathead screwdriver) is explained based on Figures 4 and 5. In this example, in addition to the connector removal as in Example 1, the same general-purpose tool can also be used to mate the connector.

[0062] One connector 10 of Example 1 is provided with a support portion 12 for pulling in the mating housing 20h. The housing 20h of the other connector 20 is provided with a pull-in portion 22 that faces the pull-in support portion 12 in the mating direction, and the connectors can be mated by a multiplying mechanism that uses a general-purpose tool 60 as a lever.

[0063] Figure 5(a) shows the state in which, to begin mating, the worker pushes the other connector 20 to a position just before the peak contact load of the terminals occurs. At this time, the tapered end 31b of the male terminal is pushed in just before passing the contact part 41b of the female terminal. In this state, the tip 61 of the general-purpose tool 60 is inserted into the gap between the support part 12 and the retracting part 22 when retracting.

[0064] Because support part 12 serves as a fulcrum when retracting, the wall thickness 12t is set to a strength that takes into consideration the safety factor mentioned above so that it will not break when subjected to the load F3 required for connector mating plus the load F1 (= F3·L3 / L1) applied to force point 62 of general-purpose tool 60 using a leverage ratio. L1 is the distance from force point 62 to retraction support part 12b, and L3 is the distance from general-purpose tool tip 61a to 12b.

[0065] The lead-in portion 22 has a gap large enough to insert a general-purpose tool when the operator pushes in the other connector 20, and a stopper 22c is provided to prevent the general-purpose tool from being inserted too far, in a position that ensures the necessary leverage. In addition, the wall thickness 23t is set to a strength that takes into account the safety factor mentioned above when a connector mating force F3 is applied.

[0066] Figure 5(b) shows the state where the other connector 20 is pulled in with a general-purpose tool, completing the connector mating. At this point, the housings butt against each other (walls 16 and 26), and the tapered end 31b of the male terminal passes through the contact part 41b of the female terminal, ensuring sufficient contact between the terminals.

[0067] When inserting tip 61 of general-purpose tool 60 into the gap between support portion 12 and retraction portion 22 during retraction, tip 61 is inserted until it hits stopper 22c. When retracting, the general-purpose tool is used as a lever with support portion 12b as a fulcrum to push retraction portion 22 and mate the other connector 20, and the general-purpose tool shifts from fulcrum portion 12b, preventing tip 61a from coming off retraction portion 22.

[0068] This concludes the explanation of connector mating using a general-purpose tool. Even if the power-assist mechanism is eliminated, connector mating and unmating can still be performed using a general-purpose tool in later processes in the vehicle assembly process. This allows mating work to be performed using automated machines and motion-assist devices in the vehicle assembly process, eliminating the need for a power-assist mechanism.

[0069] In addition, Patent Document 4, which, like the present invention, has an opening in the mating housing accommodating wall, has a dedicated lever-based multiplying mechanism for the mating operation only, and a bearing part (reference number 12 in the subject document) that supports the lever pivot shaft (reference number 20 in the subject document) to prevent the lever from coming off. However, since there is no stopper equivalent to 22c in the present invention, and the lever has a large rotation angle, when a perpendicular line is drawn to the bearing supporting the lever pivot, the lever is rotated beyond this perpendicular line to ensure the amount of displacement. If the lever pivot is not supported by the bearing, the tip of the lever may scrape the housing, generating shavings. This shavings may get into the terminal contacts and lead to poor conductivity, so replacing a lever with a pivot with a general-purpose tool without a pivot may cause an obstacle.

[0070] Example 3-1: An example of mating and unmating a connector using general-purpose parts (bolts and nuts) is explained based on Figures 6 to 8. This example is an effective structure for products where mating and unmating operations cannot be performed from the side of the connector, as in Example 2. The locking structure between the wire protection cover 250 and the housing has already been explained in paragraph 0037 [Wire protection cover], so it will not be explained here (the same applies to the following examples).

[0071] In a pair of connectors to be mated and connected, an opening 210a is provided in the mating housing accommodating wall 210h of one connector 210, and a support portion 212 for pulling in the mating housing 220h and a support portion 213 for pushing out the mating housing are provided.

[0072] Housing 220h of the other connector 220 is provided with pull-in portion 222 that faces support portion 212 in the mating direction when pulling in, and push-out portion 223 that faces support portion 213 in the mating direction when pushing out, and through holes 214, 224a, 224b are provided in support portion 212 and pull-in portion 222 when pulling in and in support portion 213 and push-out portion 223 when pushing out, and the connectors can be mated and unmated by tightening mating bolt 290a and nut 290c and unmating bolt 291a and nut 291c, which are general-purpose parts.

[0073] The method of withdrawal is explained based on Figure 7.

[0074] Figure 7(a) shows the connectors mated, and the general-purpose bolt 291a and nut 291c are being assembled to each connector to begin disassembly.

[0075] (b) shows the bolt 291a and nut 291c attached to each connector.

[0076] In (c), a tool is inserted through the hole 254 of the wire protection cover 250 into the nut 291c attached to the other connector 220 to tighten the bolt 291a. As a result, the tip of the bolt abuts against the support part 213 when pushing out, and the nut (291c) pushes the pushing part 223, and the connector 220 is now in a detached state.

[0077] When disengaging by tightening the bolts, the tightening force decreases because the terminals are no longer in contact. At this point, the tightening work is stopped and the worker then removes the connector. After that, the bolts are loosened and bolt 291a and nut 291c are removed from connector 220 in preparation for the mating work.

[0078] The bolt and nut sizes are selected so that the mating bolt (290a) will not break under the load required to mate the connector. However, when mating, the connector is not tightened until the housings are fastened together, so the initial tightening axial force is not taken into consideration. Instead, the load capacity is calculated from the bolt strength class and effective cross-sectional area, a size that exceeds the load required for connector mating is selected, and no breakage is confirmed through analysis and prototyping. In addition, the bolt head shape can be selected from hexagonal, hexagonal, etc. depending on the connector's installation position and condition and the tools used.

[0079] For the removal bolt, a larger size is selected than the mating bolt 290a, as the tip of the bolt 291a abuts against the support part 213 when pushing out, which has a hole 214 through which the mating bolt 290a passes. The wall thickness 213t and the size of the bolt 291a are selected to ensure the strength of the aforementioned abutment part (support part 213) taking into account the safety factor mentioned above, based on the load required for the connector to be removed. If there is concern about deformation of the abutment surface, a washer 290b smaller than the applicable size of the bolt 291a is attached to prevent deformation. Also, consider using a rounded or pointed tip for the bolt tip.

[0080] The size of the through holes 214, 224a, and 224b should be the smallest diameter that can accommodate the selected bolts and washers, and ensure the necessary strength for the parts that are subjected to loads when mating and unmating. However, if you are using it at high temperatures and leaving general-purpose parts installed after mating, you must take into consideration the possibility of the through holes and washers biting in due to linear expansion, as this could damage the housing.

[0081] We recommend the square nut 291c, which has a large area between the two opposing faces (e.g., 293a) and has a high anti-rotation effect. The anti-rotation function is provided by the opposing face (293a), anti-rotation face 223a (the two opposing faces), face 293b, and butt face 223b. If sufficient anti-rotation effect can be ensured, hexagonal nut 291d (see Figure 6a) can be used instead. In that case, provide a relief 223c for the diagonal dimension. Additionally, select nuts of the same size with the same two-face width dimensions. By providing abutment surface 223b for face 293b of the square nut and abutment surface 223c for the hexagonal nut (diagonal dimension relief), it is possible to align the screw hole centers when assembling either nut with the through-hole center and secure it to the housing.

[0082] In addition, since the push-out portion 223 also receives the load necessary to separate the connector via the nut 291c, the wall thickness 223t is set to ensure strength against the same load, taking into account the safety factor mentioned above.

[0083] The mating method is explained based on Figure 8.

[0084] 8(a) shows the state in which the worker pushes the other connector 220 into the connector 210 until it reaches a position just before the peak contact load of the terminals occurs, in order to begin mating with the other connector 220. The contact state of the male terminal 230 and the female terminal 240 at this time is the same as in Example 2.

[0085] (b) shows the bolt 290a, washer 290b, and nut 290c assembled to each connector. Note that the position of surface 292b of the nut is restricted by the abutment surface 212b, and the two opposing surfaces (292a) are prevented from rotating by the anti-rotation surfaces 212a (the two opposing surfaces).

[0086] In (c), the nut 290c attached to one connector 210 and the bolt 290a attached to the other connector 220 are tightened with a tool in the same way as when disconnecting. As a result, the nut abuts against the support part 212 when retracting, and the bolt attached to the other connector pushes the retraction part 222 via the washer 290b, completing the mating of the connectors. After that, the general-purpose parts that were attached depending on the situation can be removed to complete the work.

[0087] The support part 212 is set to a wall thickness of 213t, which ensures the strength required for the load required for mating the connector, taking into consideration the safety factor mentioned above.

[0088] In addition, the wall thickness of the lead-in portion 222 is set to 223t, which ensures the strength required for the load required for mating the connector, taking into consideration the safety factor mentioned above. This concludes the explanation of mating and unmating connectors using general-purpose parts.

[0089] Example 3-2: Next, we will explain Example 3-1 using a general-purpose tool (a Phillips head screwdriver) to remove the connector, based on Figure 9.

[0090] FIG. 9(a) shows a state in which a general-purpose tool 260 is inserted into an opening 210a provided in a housing receiving wall 210h of one connector 210 for assembling a nut, and the connectors have been completely separated.

[0091] (b) is a perspective view of (a) cut at the position AA. The tip 261a of the general-purpose tool 260 is inserted from the opening 210a until it hits the abutment surface 223b. The general-purpose tool is tilted in the direction of arrow b, with the support part 213 used as the fulcrum when pushing out and the corner 223d of the pushing part 223 of the other connector 220 as the point of application, to push out the connector 220. Note that general-purpose parts are used when mating this embodiment.

[0092] Example 3-3: Next, we will explain an example where Example 3-1 is applied to a connector that is designed to be mounted on a vehicle body panel, based on Figure 10.

[0093] Figure 10(a) shows one connector 510 being assembled to a vehicle body panel 560 with a locking claw 517, and the other connector 520 being temporarily set in place. After that, the connectors are mated, and a rubber grommet 580 is used to prevent water from entering the vehicle interior through a body panel hole 561.

[0094] Due to the watertight structure provided by the grommet, one connector 510 enters the inside (interior side) of the vehicle body panel 560. This makes it difficult to assemble the nut through the opening 510a of the mating housing accommodating wall 510h, so only the release nut 591c is assembled to the housing 520h in advance. In such cases, it is possible to eliminate the opening and create a structure in which the mating nut is assembled from the rear end of the housing. However, if the release nut is damaged, it may become impossible to detach the connector, so the specifications of the applicable bolts and other information must be clearly stated in work instructions, etc.

[0095] 1(b) shows a state in which an operator temporarily sets the other connector 520 to one connector 510, and then the automatic machine 80 presses the pressing portion 551 of the wire protection cover 550 to complete the connector mating work. After that, the operator assembles the grommet 580 to the vehicle body panel 560.

[0096] (c) shows the state in which the locking claws 582 of the grommet 580 are locked into the body panel hole 561 and the water-stopping portion 581 of the grommet is pressed against the body panel 560, preventing water from entering the interior of the vehicle through the body panel hole (assembly work completed).

[0097] With this connector, once the grommet is attached to the vehicle panel, the mating status of the connector cannot be checked visually, but by mechanizing the mating process, the mating status can be detected by a sensor, making it possible to guarantee the mating of the connector. This prevents poor circuit continuity due to the connector coming loose and improves the reliability of the connector connection.

[0098] If it becomes necessary to detach the connector in a later process, the locking claw 582 of the grommet 580 is released with a general-purpose tool or the like and removed from the vehicle body panel 560. After that, the connector can be detached in the same manner as in Example 3-1 by tightening the bolt 291a to the detachment nut 591c that was previously assembled.

[0099] When mating the connector, remove the release bolt 291a, assemble the mating nut 290c to the vehicle body housing 510h from the inside of the vehicle, and then tighten the mating bolt 290a to the mating nut to complete the mating. After that, remove the general-purpose mating parts depending on the situation. Furthermore, since the housings are not fastened together when mated, it is not possible to control the tightening of the bolts by torque. Therefore, either provide a mark to indicate the mating completion position, or refer to paragraph 0114 (Method of ensuring mating by lock arm) and paragraph 0119.

[0100] This means that even if the boosting mechanism is eliminated, the connector can be mated and detached using general-purpose parts in processes such as later in the vehicle assembly process. The above is an explanation of an example of application to a connector designed to be mounted on a vehicle body panel.

[0101] Example 4: An example of mating and unmating a waterproof connector using a general-purpose tool is explained based on Figures 11 and 12. To ensure waterproof performance, mating and unmating operations are performed outside the waterproof parts of rubber plug 335 and packing 328. General-purpose parts can also be used with the same settings. In this embodiment, two operating parts are provided and operated with two general-purpose tools. The number of operating parts is determined after providing restricting ribs 310a on the housing, setting the operating parts to the optimal positions according to the arrangement of terminal accommodating parts 311, and correcting the inclination of the connectors relative to each other.

[0102] In a pair of connectors to be mated and connected, an opening 320a is provided in a mating housing accommodating wall 320h of one connector 320, and a support portion 322 for pulling in the mating housing 310h and a support portion 323 for pushing out the mating housing are provided.

[0103] The housing 310h of the other connector 310 is provided with a pull-in portion 312 that faces the mating direction and the support portion 322 when pulling in, and a push-out portion 313 that faces the mating direction and the support portion 323 when pushing out, and the connectors can be mated and unmated by a multiplying mechanism that uses a general-purpose tool 360 as a lever.

[0104] I'll explain how to leave.

[0105] With the connectors mated, to begin disassembly, insert the tip of the general-purpose tool 360 (flat-head screwdriver) into the gap between the support part 323 and the push-out part 313 when pushing out.

[0106] Since the support part 323 becomes a fulcrum when pushing out, the wall thickness is set to the load required to separate the connector, plus the force point load of the general-purpose tool 360 using a leverage ratio, and the strength is set taking into account the safety factor mentioned above so that the connector will not break under that load.

[0107] The extrusion part 313 secures a gap for the tip of the general-purpose tool to be inserted and picks it up when inserting it. The wall thickness is set to a strength that takes into account the safety factor mentioned above.

[0108] The general-purpose tool 360 is used on both sides of the operating section to push out the other connector 310. The general-purpose tool should be operated until the operating force is reduced. The worker then pulls out the connector to complete the disconnection work. Note that before starting this disconnection work, the connectors must be unlocked by the housing lock. The unlocking method will be explained later in [How to unlock the lock arm].

[0109] This section explains how to connect the connectors.

[0110] To start mating the connectors, the operator pushes the other connector 310 in until it reaches a position just before the peak reaction force against mating occurs. In this state, the tip of the general-purpose tool 360 is inserted into the gap between the support part 322 and the retraction part 312 when retracting.

[0111] Since the support part 322 becomes a fulcrum when being pulled in, the wall thickness is set to the load required for mating the connector, plus the force point load of the general-purpose tool 360 by the leverage ratio, and the strength is set taking into consideration the safety factor mentioned above so that it will not break under that load.

[0112] Lead-in portion 312 ensures a gap for inserting a general-purpose tool when the operator pushes in connector 310. In addition, the wall thickness is set to a strength that takes into account the aforementioned safety factor when the load required for connector mating is applied.

[0113] The two general-purpose tools 360 are used as levers to operate the multiplying mechanism, which pulls in the other connector 310, completing the connector mating. Note that, particularly in manual work, a means of confirming that mating is complete is necessary, not just in this example, so next we will explain a method of ensuring mating using a lock arm as a means of confirming that mating is complete.

[0114] [Method of ensuring engagement using a lock arm] The method of connector mating assurance using a lock arm that maintains the mated state of the connector is explained below with reference to Figure 12.

[0115] In the case of multi-pole connectors, the terminal contact load may result in a holding force greater than the lock arm's performance. However, since automotive connectors are susceptible to external forces such as vibration and impact, they generally have lock arms. This example is an example of a simplified locking structure that is smaller and lighter by using a general-purpose tool to release the lock.

[0116] Section AA in Figure 12 is a cross section of the part indicated in Figure 11 when mating begins. (a) to (c) in the same figure are operation flow diagrams of the lock arm from the start of mating to completion.

[0117] When the other connector 310 is pushed in (see a), cantilever-shaped lock arm 327 is displaced (see b) along inclined surface 317a and apex 317b of lock protrusion 317 of mating housing 310h. When connector 310 is further pushed in to the predetermined position where mating is complete, the lock arm returns to its original position and lock arm locking surface 327c locks into locking surface 317c of the lock protrusion (see c).

[0118] When an automated machine mates connectors, the behavior of the lock arm 327 is detected by the camera 83 of the automated machine 80. During mating, the lock arm displaces (displacement amount h1), causing the tip 327a of the lock arm to close the space 327e below the lock protection wall 327d. After that, mating is completed and a gap h2 is created, which indicates that the connector mating is complete. The detection results are input into the quality control system and saved in a database. Accurate determinations can also be made using a learning method based on these conditions.

[0119] When mating connectors using general-purpose tools and parts, just like with an automated machine, the series of movements in which the gap H2 that was temporarily closed upon mating is opened is visually confirmed. Alternatively, the connectors can be judged to be fully mated by visually checking that there is a gap and that the locking projection 317 is inserted into the lock arm locking hole 327b.

[0120] [How to release the lock arm] To release the lock arm 327, a general-purpose tool 365 (precision screwdriver) is used due to its simple shape. Select the tool to be used and create a guide groove 317d in the housing 310h to match the tip dimensions. Insert the tool along this groove, and when the lock arm is released, use the reaction force of the lock arm to secure the tool in place. This eliminates the need for the worker to hold the tool, and the other connector 310 can be pushed out using two general-purpose tools 360.

[0121] [Wire protection cover and housing locking structure] The locking structure of the wire protection cover 350 and housing 310h is the same as in other examples, so we will explain the differences. To prevent the cover from spreading outward, the housing has opening prevention protrusions 315g (in four locations). This increases the strength to prevent the cover from coming off due to the pressing load of an automatic machine or external force.

[0122] Furthermore, by providing locking protrusion 315c between two opening prevention protrusions 315g, locking in the sliding direction after the housing is assembled is possible, as locking protrusion 355c on the cover side (see cross section AA in Figure 12) is displaced outward when it passes over locking protrusion 315c, making it possible to lock in the sliding direction without providing a slit in the cover. To remove the cover, insert the general-purpose tool 365 into the groove 317d, displace the locking projection 355c on the cover side outward to release the lock, and then remove the cover. The above is an explanation of an example of mating and unmating a waterproof connector using a general-purpose tool.

[0123] Example 5: An example of mating and unmating a connector using a general-purpose tool and / or general-purpose parts is explained with reference to Figure 13. This example also provides individual mating and unmating operating parts, making it easier to ensure strength in areas where strength is required.

[0124] In a pair of connectors to be mated and connected, openings 410a and 410b are provided in the mating housing accommodating wall 410h of one connector 410, and a support portion 412 for pulling in the mating housing 420h and a support portion 413 for pushing out the mating housing are provided.

[0125] On the other hand, housing 420h of connector 420 is provided with retraction portion 422 that faces support portion 412 when retracting in the mating direction, and through holes 414a, 424a are provided in retraction portion 422 and support portion 412a when retracting, which is a general-purpose part, and connector mating is enabled by inserting bolt 490a, a general-purpose part, through this through hole and tightening it to nut 490c via washer 490b and collar 490d. Also, general-purpose tool 460 is inserted into opening 410a, and using support portion 412 when retracting as a fulcrum, the general-purpose tool is used as a lever to push out retraction portion 422, enabling connector mating.

[0126] Furthermore, housing 420h of other connector 420 is provided with push-out portion 423 that faces support portion 413 for pushing out in the mating direction, and push-out portion 423 is provided with through-hole 424b, and the connector can be removed by inserting general-purpose bolt 491a from hole 454b of wire protection cover 450 and tightening it with nut 490c. Also, the connector can be removed by inserting general-purpose tool 460 into opening 410b and using the general-purpose tool as a lever to push out push-out portion 423 with support portion 413 for pushing out as a fulcrum.

[0127] This allows for flexibility in setting the wall thickness 422t of the pull-in section 422, which requires strength, making it easier to ensure strength, and when the load required for connector mating is applied in addition to the wall thickness 412t, each wall thickness is set to a strength that takes into account the safety factor mentioned above. Also, because the bolt size can be made the same, the diameter of the through hole 424b can be made smaller, increasing the strength of the push-out section 423. It also makes it possible to share general-purpose parts used for mating and unmating.

[0128] Figure 13(c) shows the connector mating state using a general-purpose tool, and Figure 13(d) shows the connector mating state using a general-purpose part. The general-purpose part collar 490d is installed to prevent the male terminal 430 from being deformed by the bolt tightening tool. The above is an explanation of an example of mating and unmating a connector using general-purpose tools and / or general-purpose parts. [Explanation of symbols]

[0129] 10 One connector (male connector) 10a opening 10h Mating housing accommodation portion (male housing) 12 Support part when retracting 13 Support for extrusion 20 Other connector (female connector) 20h Mating housing (female housing) 22 Retraction section 23 Extrusion section 51 Pressing section 60 General-purpose tools (drivers) 80 Robot Arm (Automatic Machine) 290a General-purpose parts (bolts)

Claims

1. In a pair of connectors to be mated and connected, a support portion for pushing out the mating housing is provided in at least one opening that penetrates the side wall of the mating housing accommodation wall of one connector in a direction perpendicular to the mating direction, and after mating is complete, at the start of disengagement, a push-out portion is provided in the housing of the other connector that faces the support portion for pushing out in the mating direction, and the operating force when pushing out using a rod-shaped tool is reduced by the principle of leverage, with the support portion as the fulcrum and the push-out portion as the point of application, making it possible to disengage the connectors.

2. 2. A connector as described in claim 1, wherein a support portion for pulling in the mating housing is provided in at least one opening formed in the side wall of the mating housing accommodating wall of one of the connectors in a direction perpendicular to the mating direction, and when mating begins, a pulling portion is provided in the housing of the other connector that faces the support portion for pulling in in the mating direction, and the operating force is reduced by using a rod-shaped tool when pulling in by using the principle of leverage, with the support portion as the fulcrum and the pulling portion as the point of application, thereby making it possible to mate the connectors.

3. A through hole is provided in the push-out portion, a nut is assembled in a state where it is in contact with the push-out portion, a bolt is assembled from the through hole and tightened to the nut, the tip of the bolt is butted against the support portion used when pushing out the bolt, and the push-out portion is pressed with the nut, thereby enabling the connector to be separated, a support portion for pulling in the housing of one of the connectors by a fastening part facing the pull-in portion in the mating direction at the start of mating, and a hole penetrating the support portion and the pull-in portion; The nut is assembled while it is in contact with the retraction portion, the bolt is inserted through the through hole and tightened to the assembly nut, the bolt head is butted against the support portion when retracting with the fastening part, and the retraction portion is pressed with the nut, allowing the connector to be mated. Alternatively, the connector according to claim 2, wherein the nut is assembled while being abutted against the support portion when being pulled in by the fastening part, the bolt is tightened into the assembly nut from the through hole, the bolt head is butted against the pull-in portion and the pull-in portion is pressed by the bolt, thereby enabling the connector to be mated.

4. In a pair of connectors to be mated and connected, a support portion for pushing out at least one mating housing is provided on the bottom wall of the mating housing accommodation wall of one connector, and after mating is complete, at the start of disengagement, a push-out portion with an open through hole is provided on the housing of the other connector facing the support portion for pushing out in the mating direction, a nut is provided in contact with the push-out portion, a bolt is fastened to the assembly nut through the through hole, and the tip of the bolt is butted against the support portion for pushing out, and the push-out portion is pressed with the nut, allowing the connectors to be disengaged.

5. 5. The connector according to claim 1, wherein the other connector is provided with a pressing portion for mating with the one connector, thereby making the mating operation of the connectors more efficient.

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