Battery Connector Assembly Verification Using Acoustic Sensing
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Solution Overview
Problem
Verifying the proper assembly of small connectors, such as quick connectors in battery electric vehicle battery packaging, is challenging due to their small size and the difficulty of visual inspection.
Innovation Solution
A method and system that capture audio signals during the assembly of connectors and use these signals to verify proper assembly in real-time, employing audio sensing devices, position tracking, and machine learning to analyze the audio features and predict proper or improper assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual inspection by operator is used to verify connector assembly, then verification process is simple and low-cost, but measurement precision is insufficient due to small connector size (approximately 10 mm)
Solution Approach 1:
The patent replaces the mechanical visual inspection method with an acoustic sensing system. Audio sensors capture sound signals generated during connector assembly, and machine learning models analyze these signals to detect proper assembly. This substitution enables precise verification of small connectors (approximately 10 mm) without relying on human visual inspection limitations.
2Object-affected harmful factors
If audio sensing device is positioned far from operator to ensure safety, then operator safety is improved, but audio signal capture quality deteriorates
Solution Approach 1:
The patent implements a dynamic positioning system where the audio sensing device is not fixed but can move or be repositioned based on operational needs. The system tracks operator position and adjusts sensor placement to maintain optimal audio capture while respecting safety boundaries. This dynamic approach allows the system to adapt between safety distance requirements and signal quality needs.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor both operator position and audio signal quality. Based on this feedback, the system adjusts the positioning of audio sensors or activates multiple sensors at different locations to ensure adequate signal capture while maintaining safe operator distances. The feedback loop enables real-time optimization of the safety-quality tradeoff.
3Measurement precision
If multiple audio sensing devices are deployed to improve verification accuracy, then measurement precision is improved, but device complexity and cost increase
Solution Approach 1:
The patent divides the audio sensing function across multiple distributed sensors rather than using a single complex sensor. Each audio sensor captures sound signals from specific zones around the assembly area. The system processes signals from multiple sensors to create a comprehensive acoustic picture, improving verification accuracy through spatial distribution of sensing elements.
Solution Approach 2:
The patent designs the audio sensing devices to serve multiple functions: detecting connector assembly sounds, tracking operator position, monitoring environmental noise, and providing spatial audio mapping. This multi-functionality reduces the need for separate specialized devices, thereby managing system complexity while maintaining enhanced verification capabilities.
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
This approach enables real-time verification of connector assembly, providing immediate feedback to operators and reducing the risk of improper connections, which can lead to safety threats and increased costs.
Implementation Method 1
capturing at least one audio signal from within a footprint of an assembly line during the assembly of the connector
Data Source
AI summary
A method of verifying an assembly of a connector, the method including capturing at least one audio signal from within a footprint of an assembly line during the assembly of the connector; and verifying the assembly of the connector based on the at least one audio signal.