Connector Position Assurance Indicator Barcode Verification
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Solution Overview
Problem
Automotive Original Equipment Manufacturers face challenges in ensuring proper mating of electrical connectors, as assembly operators may fail to move the connector position assurance device (CPA) to the proper seated position, leading to incomplete connections, and there is a need to verify the CPA's closed position post-mating.
Innovation Solution
A connector assembly with movable indicator features that form a complete machine-readable barcode (1D, 2D, or 3D) only when fully mated, using a CPA device coupled to the connector body, which is restricted from moving to the joined position until the connector is fully seated, ensuring proper mating and allowing verification through sensors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a CPA device is provided to ensure proper mating, then connection reliability is improved, but assembly operators may fail to move the CPA to the proper seated position, leading to inability to verify proper connection
Solution Approach 1:
The patent uses visual indicators that change appearance based on CPA position. The indicator features include different colors or visual states that are visible when the CPA is in the seated position, allowing operators to easily verify proper connection without complex procedures. This resolves the contradiction by maintaining reliability while dramatically improving verification ease through intuitive visual feedback.
Solution Approach 2:
The patent implements a feedback mechanism where the visual indicator provides immediate information about CPA position. The indicator features are configured to show a specific visual state only when the CPA is properly seated, creating a closed-loop feedback system that guides operators and confirms proper assembly. This resolves the verification difficulty by providing real-time feedback on connection status.
2Ease of operation
If indicator features are always visible, then verification is simplified, but the ability to confirm proper mating is reduced since there is no change in appearance
Solution Approach 1:
The patent employs dynamic visual indicators that change their appearance or visibility based on the CPA position. The indicator features are designed to assume a specific visual configuration only when the CPA is in the seated position, transitioning from one state to another as the CPA moves. This resolves the contradiction by providing both continuous visibility for ease of operation and position-dependent visual changes for precise verification.
Solution Approach 2:
The visual indicator is segmented into multiple features that can be independently positioned or activated. The first and second indicator features are disposed at different locations and can be independently configured, allowing the system to provide both general visibility and specific position confirmation. This segmentation enables the indicator to serve dual purposes: general visibility for ease of operation and position-specific configuration for precise verification.
3Reliability
If the connector assembly includes recordable features to log presence and position, then verification capability is improved, but device complexity increases
Solution Approach 1:
The patent uses visual indicator features that create a visual copy or representation of the CPA position and connection status. Instead of complex electronic sensors and data storage systems, the indicator features provide a visual copy of the mating state that can be easily observed and recorded. This resolves the contradiction by providing verification capability through simple visual copying rather than complex electronic systems.
Solution Approach 2:
The indicator features are self-configuring and self-indicating, requiring no external power source, electronics, or complex mechanisms. The features automatically assume their verified position or appearance based on the CPA state, providing verification capability through passive visual indication. This self-service approach maintains reliability while minimizing device complexity by eliminating the need for active verification systems.
Data Source
AI summary
A connector comprises a connector body having a mating interface configured to engage a complementary mating connector, a first indicator feature carried by the connector body, the first indicator feature having a first partial visual identifier disposed thereon, and a second indicator feature carried by the connector body having a second partial visual identifier disposed thereon, wherein the first and second indicator features are movable relative to each other between a separated position and a joined position, characterized in that the first and second indicator feature form a complete visual identifier only when in the joined position, wherein the first and second indicator features are in the separated position when the connector body is not fully mated relative to the mating connector, and wherein the first and second indicator features are in the joined position responsive to the connector body being fully mated to the mating connector.