Connector Coupling Verification via Acoustic Signal Analysis
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Solution Overview
Problem
Existing methods for verifying connections between components, such as electrical or mechanical connectors, are not always accurate and can be impractical in confined spaces or when visual inspections are obstructed, leading to potential incomplete or low-quality connections.
Innovation Solution
A system utilizing an audio transducer and electronic processor to detect and analyze the sound generated during connector coupling, filtering the audio signal in both frequency and time domains to compare with a predetermined pattern for proper coupling verification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual inspection is used to verify connections, then the connection completeness can be checked, but the inspection accuracy is insufficient and it cannot be performed in confined spaces or when line of sight is obstructed
Solution Approach 1:
The patent replaces the mechanical/visual inspection system with an acoustic detection system. An audio transducer captures the unique coupling sound generated during connector engagement, and an electronic processor analyzes this sound to verify connection completeness. This substitution eliminates the need for direct visual access to the connection point, allowing verification in confined spaces and obstructed areas while improving both reliability and accessibility.
2Reliability
If a secondary mechanical locking mechanism is used to achieve connection assurance, then the connection reliability is improved, but the manufacturing cost increases and assembly time is extended
Solution Approach 1:
The patent replaces the secondary mechanical locking mechanism with an acoustic verification system. Instead of adding physical locking components that require manual engagement and verification, the system uses an audio transducer to capture and analyze the coupling sound, automatically determining connection status. This eliminates the need for additional mechanical parts and manual locking steps, maintaining high reliability while significantly improving assembly speed and productivity.
Solution Approach 2:
The coupling process itself generates the verification signal. The unique sound produced during proper connector engagement serves as the verification indicator, eliminating the need for separate verification mechanisms or steps. The system leverages the inherent acoustic signature of the coupling event to automatically confirm connection status, making the verification process intrinsic to the assembly operation.
3Measurement precision
If multiple visual inspections are performed to verify connections, then the connection accuracy can be improved, but the inspection time and complexity increase
Solution Approach 1:
The patent replaces multiple sequential visual inspections with a single acoustic analysis operation. The audio transducer captures the coupling sound, and the electronic processor rapidly analyzes the acoustic signature to determine connection completeness. This single-step acoustic verification achieves the same or better accuracy as multiple visual inspections while dramatically reducing the time required, as acoustic analysis occurs automatically and instantaneously without manual intervention.
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 method provides a reliable and efficient means to ensure accurate connections by analyzing the unique sound produced during coupling, reducing the likelihood of incomplete or low-quality connections and overcoming visual inspection limitations.
Implementation Method 1
an audio transducer and an electronic processor. The electronic processor is communicatively coupled to the audio transducer. The electronic processor is configured to determine a velocity of the first connector when the first connector passes a set point when the first connector is moved to the second connector to form a coupling. The coupling generates a sound.
Implementation Method 2
The audio signal is filtered a first time in the frequency domain and a second time in the time domain, resulting in a filtered spectrogram.
Implementation Method 3
The audio signal is filtered a first time in the frequency domain and a second time in the time domain, resulting in a filtered spectrogram.
Data Source
Figure 1
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Figure 3A
AI summary
A system and method for verifying a connection between a first connector and a second connector. The system includes an audio transducer and an electronic processor. The electronic processor is communicatively coupled to the audio transducer. The electronic processor is configured to determine a velocity of the first connector when the first connector passes a set point when the first connector is moved to the second connector to form a coupling. The coupling generates a sound. The electronic processor calculates a time interval to formation of the coupling based on the velocity detected at the set point and a position of the second connector. The electronic processor receives, from the audio transducer, an audio signal during the time interval. The audio signal includes the sound generated when the coupling is formed. The electronic processor generates and analyzes the audio signal and identifies the sound of the coupling within the audio signal. The audio signal is filtered a first time in the frequency domain and a second time in the time domain, resulting in a filtered spectrogram. The filtered spectrogram is compared to a predetermined sound pattern to generate a comparison. The electronic processor then determines if the first connector and the second connector are properly coupled based on the comparison.