Connector Position Assurance Indicator for Full-Mating Verification
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Solution Overview
Problem
Automotive Original Equipment Manufacturers (OEMs) face challenges in ensuring proper mating of electrical connectors, as assembly operators often 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 of connectors, then connection reliability is improved, but assembly operators may fail to move the CPA to the proper seated position, leading to incomplete verification
Solution Approach 1:
The patent implements visual feedback through indicator features that change appearance based on CPA position. The indicator features include a first feature on the connector body and a second feature on the CPA device that align to form a complete visual pattern (such as a filled circle or square) only when the CPA is in the correct seated position. This immediate visual feedback guides operators to properly position the CPA and verifies correct installation.
Solution Approach 2:
The patent employs color changes as a visual indication mechanism. The indicator features utilize different colors or shading patterns that become visible or align to form a complete visual identifier when the CPA is properly positioned. For example, the indicator may show a complete colored shape or pattern only when the CPA device is fully seated, providing intuitive visual confirmation of correct positioning.
2Difficulty of detecting and measuring
If indicator features are made visible to verify CPA position, then verification capability is improved, but the complexity of the connector assembly increases
Solution Approach 1:
The patent merges the verification function into the existing CPA device structure. The indicator features are integrated directly onto the connector body and CPA device components that already exist for mechanical functioning. The first indicator feature is formed on the connector body wall, and the second indicator feature is formed on the CPA device itself, combining structural and indication functions without adding separate verification mechanisms.
Solution Approach 2:
The indicator features serve multiple functions: they provide visual verification of CPA positioning, identify the connector type or configuration, and can potentially encode additional information about the connection state. The same structural components that make up the CPA device also serve as the medium for displaying verification information, eliminating the need for separate indication 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.