Adjustable Connector Staging for Precise Robotic Vehicle Assembly

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Solution Overview

Problem

Existing connector staging systems for vehicle electrical connections are complex and costly due to integrally-molded features, complicating accurate and efficient 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 repeatable assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If integrally-molded features are used in connectors, then accurate and repeatable handling and positioning are improved, but device complexity and manufacturing cost increase

Engineering Contradiction:

Improveaccurate and repeatable handling and positioningVSAvoidcomplex mold tooling

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The installation subassembly is divided into separate components including a connector retainer, positioning features, and engagement mechanisms that are adjustably coupled rather than integrally molded. This segmentation allows each feature to be independently optimized and adjusted without requiring complex integrated mold tooling.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The installation subassembly incorporates adjustably-coupled components that allow dynamic positioning and alignment adjustments during the assembly process. This enables accurate connector positioning through adjustment mechanisms rather than relying solely on precision molded features.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If integrally-molded features are used in connectors, then accurate and repeatable handling and positioning are improved, but manufacturing cost increases

Engineering Contradiction:

Improveaccurate and repeatable handling and positioningVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

By segmenting the connector assembly into a connector body and a separate installation subassembly with distinct features, the system avoids the need for expensive integrally-molded multi-function features. Each component can be manufactured more simply and assembled together.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The installation subassembly serves multiple functions including positioning, retention, and alignment of the connector. This multi-functional subassembly replaces the need for multiple specialized integrally-molded features in the connector itself, reducing overall manufacturing complexity and cost.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If adjustable coupling is used in installation subassembly, then adaptability and ease of operation are improved, but device complexity increases

Engineering Contradiction:

Improveadaptable positioningVSAvoidadjustably-coupled components

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The adjustably-coupled components provide dynamic adaptability for positioning and alignment while using straightforward mechanical adjustment mechanisms. This allows the system to accommodate variations in connector dimensions and positioning requirements without requiring overly complex adjustment systems.

Inventive Principle:

Principle #15Dynamics

Data Source

PatentEP4651323A1Connector staging system and method

Publication Date: 2025.11.19 APTIV TECHNOLOGIES AG

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AI summary

A staging system (10) for robotically engaging a connector (12) to facilitate assembly of the connector in a vehicle includes a substrate (14) and an installation subassembly (16). The installation subassembly (16) is configured to be removably-coupled to the substrate (14) to facilitate robotic engagement of the connector (12). The installation subassembly (16) includes a primary component (26) and a secondary component (28) adjustably-coupled to the primary component.