Adjustable Connector Staging for Accurate Robotic Vehicle Assembly
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Solution Overview
Problem
Existing connector staging systems for vehicle electrical connections are complex and costly due to the need for intricate mold tooling, hindering efficient and accurate assembly.
Innovation Solution
A staging system comprising a substrate and an installation subassembly with adjustably coupled primary and secondary components, allowing for robotic engagement and securement of connectors, facilitating efficient and accurate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complex mold tooling is used to create integrally-molded features on connectors, then the connectors can be accurately handled and positioned during assembly, but the cost and complexity of the connector increases
Solution Approach 1:
The invention divides the connector assembly system into separate components: the connector body and the installation subassembly. Instead of molding features directly into the connector, the system uses a separate subassembly with positioning features that interfaces with the connector during installation. This segmentation eliminates the need for complex integrally-molded features while maintaining positioning accuracy.
Solution Approach 2:
The installation subassembly acts as an intermediary device between the connector and the final installation location. It provides the positioning and alignment features that would otherwise require complex mold tooling, allowing simple connector designs to achieve precise installation through the mediating subassembly.
2Manufacturing precision
If integrally-molded features are added to connectors for accurate handling, then assembly accuracy improves, but the manufacturing cost increases
Solution Approach 1:
By separating the positioning functionality from the connector body and placing it in the installation subassembly, the invention eliminates the need for expensive integrally-molded features on the connector. This allows manufacturers to produce simpler, lower-cost connectors while maintaining assembly accuracy through the subassembly.
Solution Approach 2:
The installation subassembly appears to be a disposable or single-use component that provides precise positioning during installation but is not permanently retained. This approach is more economical than creating permanent integrally-molded features on expensive connector assemblies, as the positioning function is provided by a cheaper, temporary subassembly.
3Device complexity
If fixed-configuration staging systems are used, then the system structure is simple, but it cannot accommodate various connector sizes and configurations
Solution Approach 1:
The installation subassembly incorporates adjustable components that allow the system to adapt to different connector sizes and configurations. The subassembly can be reconfigured for various connector types while maintaining a relatively simple overall system structure, resolving the trade-off between simplicity and versatility.
Solution Approach 2:
The installation subassembly is designed as a universal component that can accommodate multiple connector types, sizes, and configurations. This multi-functional subassembly replaces the need for multiple specialized fixtures, maintaining system simplicity while providing broad adaptability across different connector variants.
Data Source
AI summary
A staging system for robotically engaging a connector to facilitate assembly of the connector in a vehicle includes a substrate and an installation subassembly. The installation subassembly is configured to be removably-coupled to the substrate to facilitate robotic engagement of the connector. The installation subassembly includes a primary component and a secondary component adjustably-coupled to the primary component.