Bridge Connector Interface for Mixed Harness Layouts
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Solution Overview
Problem
Existing electrical connector systems face challenges in integration and assembly due to varying sizes and arrangements of wire harness terminals, requiring different configurations for each vehicle, which complicates the connection of wire harness connectors to control modules within a fleet of vehicles.
Innovation Solution
A bridge connector system that includes a housing with chambers for connectors and bridge connectors, which are electrically connected to harness connectors, allowing for a common interface with control circuit boards while accommodating different harness connector sizes and arrangements, thereby simplifying integration and assembly across various vehicle models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If different sized connectors and contacts are used to accommodate various wire harness configurations, then adaptability to different vehicle models is improved, but device complexity increases making integration and assembly difficult
Solution Approach 1:
The connector system is divided into separate modules: a control module with a control circuit board, wire harness connectors, and intermediate connectors. Each module can be independently configured and assembled, allowing different wire harness arrangements to be accommodated without redesigning the entire system. The intermediate connectors act as separate adaptation modules between the wire harness connectors and the control circuit board.
Solution Approach 2:
Intermediate connectors are introduced as mediator components between the wire harness connectors and the control circuit board. These intermediate connectors have contacts that can be arranged in different configurations to match various wire harness arrangements, while their other contacts maintain a standardized arrangement that interfaces with the control circuit board. This intermediary layer absorbs the variability of different wire harness configurations.
2Adaptability or versatility
If different arrangements of board terminals are used for different vehicles, then adaptability to various vehicle models is improved, but ease of manufacture deteriorates
Solution Approach 1:
The control circuit board is designed with a universal standardized interface that can work with multiple intermediate connector configurations. The intermediate connectors serve multiple functions: they adapt to different wire harness arrangements while maintaining compatibility with the standardized control circuit board interface. This universal design allows the same control module to be used across different vehicle models with varying wire harness configurations.
3Ease of manufacture
If standardized connector sizes are used across all applications, then ease of manufacture is improved, but adaptability to different wire harness configurations deteriorates
Solution Approach 1:
The intermediate connectors exhibit local quality by having different contact configurations in different regions. One set of contacts is arranged to match the standardized control circuit board interface, while another set of contacts is arranged to match specific wire harness connector configurations. This allows standardized manufacturing of the control circuit board while maintaining adaptability to various wire harness arrangements through the intermediate connectors.
Data Source
AI summary
A bridge connector system includes a housing having one or more chambers, one or more connectors held in the corresponding chambers, one or more bridge connectors received in the corresponding chambers and electrically connected to the corresponding connectors, and one or more harness connectors coupled to the housing and being electrically connected to the corresponding bridge connectors. The bridge connectors electrically connect the harness connectors with the connectors.