Plug-In Connector Assembly With CPA-Locked Final Position Check
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Solution Overview
Problem
Existing plug-in connector assemblies for high-current applications and multi-pin connections lack a reliable mechanism to ensure that the actuation element has reached the final plugged position, leading to potential incorrect connections that are difficult to detect visually and haptically.
Innovation Solution
A plug-in connector assembly with an actuation element and a connector position assurance (CPA) that is displaced between unlocking and locking positions, where the CPA's displacement is dependent on the plugged position, ensuring a correct connection is established before allowing the CPA to lock, thereby preventing incorrect connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a CPA is provided that only indicates the actuation element has reached the second position, then the device complexity is reduced, but the reliability of connection indication is insufficient
Solution Approach 1:
The patent combines the CPA displacement function with the plug-in connector's plugging motion. The CPA is integrated into the connector housing and its displacement is coupled to the relative movement between the plug-in connector and mating plug-in connector, ensuring that CPA position reflects both actuation element position and actual connection status.
Solution Approach 2:
The system provides feedback through the CPA's position to indicate whether the connection is correct. The CPA can only be displaced to the locking position when the plug-in connector reaches the final plugged position, giving visual/haptic feedback to the operator that the connection is proper.
2Ease of operation
If the CPA locks the actuation element without ensuring final plugged position, then the ease of operation is improved, but the safety of electrical connection is compromised
Solution Approach 1:
The patent requires that the plug-in connector first reach the final plugged position and establish proper electrical contact before the CPA can be displaced to the locking position. This preliminary action ensures correct connection is established before the locking function activates.
Solution Approach 2:
The CPA acts as an intermediary mechanism between the actuation element and the locking function. It mediates the locking process by requiring both the actuation element to be in the second position and the plug-in connector to be in the final plugged position before allowing the CPA to lock.
3Reliability
If the CPA displacement is blocked depending on plugged position, then the reliability of connection indication is improved, but the device complexity increases
Solution Approach 1:
The patent merges the CPA displacement mechanism with the plug-in connector's plugging motion. The CPA is integrated into the connector housing and its displacement is coupled to the relative movement between the plug-in connector and mating plug-in connector, ensuring that CPA position reflects both actuation element position and actual connection status.
Data Source
AI summary
A plug-in connector assembly. The assembly includes: a plug-in connector with a plug-in connector housing; a mating plug-in connector with a mating plug-in connector housing; an actuation element; a CPA. The plug-in connector has a plugged position relative to the mating plug-in connector and can be plugged to the mating plug-in connector from a starting plugged position up to a final plugged position along a plugging direction. The actuation element can be displaced between a first position and a second position and is designed to reduce a plug-in force when connecting the plug-in connector to the mating plug-in connector. When the actuation element is displaced from the first position to the second position, the plug-in connector is displaced from the starting plugged position to the final plugged position. The CPA can be displaced between an unlocking position and a locking position.