3D-Printed ECU Adapter for Non-Destructive Breakout Box Connection
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Solution Overview
Problem
Connecting a breakout box between an electrical control unit (ECU) and an electrical wiring system in a vehicle is complicated due to the need to maintain the existing connection between the ECU and the electrical system without affecting or destroying it, especially with the variety of electrical connectors used in different vehicle models and manufacturers.
Innovation Solution
An adapter is formed using a 3D printer based on the connector features of the ECU, comprising an electrical plug connector with a gender opposite to the ECU's jack connector, allowing a three-way connection with the breakout box, sensors, and the electrical system, without mechanically interacting with the existing connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a breakout box is connected to the electrical system by mechanically interacting with existing connectors, then connection can be established, but the existing connection between ECU and electrical system may be affected or destroyed
Solution Approach 1:
The patent introduces an adapter as an intermediary component that connects between the breakout box and the electrical system without requiring mechanical interaction with the existing ECU connector. The adapter has a first connector interface that mates with the breakout box and a second connector interface that connects to the electrical system, thereby mediating the connection and preserving the integrity of the original ECU-wiring connection.
2Ease of manufacture
If standard electrical connectors are used for different vehicle models and manufacturers, then manufacturing and maintenance are simplified, but adaptability to connect breakout boxes to various ECUs is reduced
Solution Approach 1:
The patent employs dynamic adaptability through the adapter design, where the adapter body is configured with specific geometric features (such as recesses, protrusions, or dimensional variations) that correspond to the unique characteristics of different ECU jack connectors. This allows the adapter to dynamically adapt to various connector types while maintaining standardized manufacturing processes for the adapter itself.
Solution Approach 2:
The connection system is segmented into distinct functional components: the standardized breakout box interface, the adaptive adapter body, and the electrical system connector. This segmentation allows the adapter to serve as a customizable intermediate layer that bridges standardized and non-standardized interfaces without requiring changes to either the breakout box or the electrical system.
3Adaptability or versatility
If custom adapters are designed for each specific ECU connector type, then adaptability is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The adapter is designed with universal adaptability features that allow a single adapter design to accommodate multiple ECU connector types. The adapter body incorporates configurable geometric parameters (such as adjustable recess depths, universal mounting features, or modular contact arrangements) that can be adapted to different connector standards without requiring completely different adapter designs, thereby reducing overall system complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Facilitates swift and non-destructive connection of the breakout box, reducing on-site time and enabling communication listening between the ECU and the vehicle's electrical system, while maintaining the integrity of the existing connections.
Implementation Method 1
a 3D model for the adapter is provided to a 3D printer, which forms the adapter body
Data Source
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AI summary
The present disclosure generally relates to a novel concept of forming an adapter for an automotive application to be used for connecting a breakout box in-between an electrical control unit (ECU) of a vehicle and an electrical wiring system comprised with the vehicle. The adapter is formed using a 3D printer based on a construction of an electrical connector design provided with the ECU. The present disclosure also relates to a corresponding system and a computer program product.