Acoustic Connector Mating Verification
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Solution Overview
Problem
Existing connector mating assurance systems fail to reliably ensure proper mating of electrical connectors, especially in noisy environments like automotive assembly factories, where vibrations can cause connectors to loosen and fail, and conventional methods are either costly or labor-intensive.
Innovation Solution
A user-worn sensor unit with an audible sensor and controller that detects the audible sound of connector mating, providing feedback to the user through audio, visual, or tactile means, and optionally communicates with a host controller for secondary verification, using multiple microphones to enhance reliability and filter out background noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical assurance tests are used to detect connector mating status, then the testing method is simple, but the detection reliability is insufficient in noisy environments
Solution Approach 1:
The patent replaces conventional electrical testing methods with an acoustic detection system. A sensor detects the specific acoustic signature (click sound) generated when the latch mechanism engages with the connector housing. This acoustic field-based detection method substitutes the electrical signal-based method, providing reliable detection independent of electrical connection status and immune to electrical noise interference.
Solution Approach 2:
The system provides visual feedback through color-coded indicators (e.g., green LED for proper mating, red LED for improper mating) that change state based on the detected acoustic signal. This visual transformation of the detection result allows operators to quickly assess connector mating status without being affected by acoustic noise, converting the acoustic detection into a visually readable format.
2Reliability
If a double casing system is used to verify connector mating, then the mating verification is more reliable, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces the mechanical double-casing verification system with an acoustic sensor-based detection system. Instead of requiring a second protective case that only fits when connectors are properly mated, the system uses a lightweight acoustic sensor to detect the latch engagement sound, providing verification without adding mechanical complexity or requiring additional structural components.
Solution Approach 2:
The connector mating verification system uses the existing latch mechanism's own acoustic signature as the verification signal. The latch engagement naturally produces a distinctive click sound that serves as its own verification indicator, eliminating the need for separate verification mechanisms or additional components.
3Measurement precision
If acoustic sensors are placed near the mating zone to detect connector latching sounds, then the detection accuracy improves, but the system becomes more sensitive to background noise
Solution Approach 1:
The system incorporates feedback through visual indicators (LEDs) that provide immediate confirmation of detected mating events. When the acoustic sensor detects a sound matching the latch engagement signature, the system provides visual feedback to confirm proper detection, allowing operators to verify the detection accuracy without being confused by background acoustic noise.
Solution Approach 2:
The system uses color-coded visual indicators to represent different detection states, transforming the acoustic detection result into a noise-immune visual signal. Green indicates successful latch detection, red indicates failure to detect, and yellow may indicate ambiguous conditions requiring re-mating. This color transformation allows operators to interpret detection results without being affected by background acoustic interference.
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
The system effectively ensures proper connector mating by providing immediate and reliable feedback to the assembler, reducing the risk of connector failure due to vibration and improving assembly efficiency and accuracy without increasing costs or labor time.
Implementation Method 1
The sensor unit has an audible sensor configured to be located in a vicinity of a mating zone for electrical connectors. The audible sensor is configured to detect an audible sound when the electrical connectors are mated.
Data Source
AI summary
A connector mating assurance system includes a user-worn sensor unit configured to be worn on or near a user's hand. The sensor unit has an audible sensor configured to be located in a vicinity of a mating zone for electrical connectors. The audible sensor is configured to detect an audible sound when the electrical connectors are mated. The system includes a user-worn controller connected to the audible sensor. The controller receives audio signals from the audible sensor, processes the audio signals to determine a connector mating status, and provides feedback to the user relating to the connector mating status.