Connector Force Verification Using Load Cells for Secure Seating
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Solution Overview
Problem
Existing methods for testing the insertion force of automotive connectors fail to ensure proper alignment and secure seating, leading to potential disconnection during vehicle operation due to misalignment or incomplete seating, despite passing conventional insertion and continuity tests.
Innovation Solution
A test apparatus using a load plate with orthogonal axes and load cells to measure and verify the magnitude and location of the plugging force applied to electrical components, assisted by a processor to compare against predetermined thresholds and provide real-time feedback on alignment and force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional insertion force testing with microswitches is used, then insertion force magnitude can be verified, but the location of force application cannot be determined leading to potential misalignment
Solution Approach 1:
The load plate is divided into multiple segments with individual load cells positioned at different locations. Each load cell measures force at its specific position, allowing the system to segment the measurement of both magnitude and location of applied force. The processor then integrates data from all segments to determine the complete force vector and application point.
Solution Approach 2:
The load plate acts as an intermediary element between the connector and the load cells. It transfers the applied force to multiple load cells positioned at known locations, enabling indirect measurement of both force magnitude and application location through the relationship between load cell readings and their geometric positions on the plate.
2Reliability
If manual push-click-tug testing is performed, then operator can verify connector seating, but the process is time-consuming and prone to human error
Solution Approach 1:
The system provides immediate automated feedback through the processor that compares measured force magnitude and location against predetermined acceptance criteria. This real-time feedback eliminates the need for manual verification steps (push-click-tug) and reduces testing time while maintaining or improving reliability through objective, consistent measurement and comparison.
Solution Approach 2:
The testing system performs self-verification by automatically measuring force parameters, comparing them against stored criteria, and determining pass/fail status without requiring operator intervention. The apparatus serves itself by integrating sensing, data processing, and decision-making functions into an automated workflow.
3Force
If insertion force is applied without precise location control, then connector may insert with sufficient force, but misalignment causes insecure seating and potential disconnection
Solution Approach 1:
The load plate incorporates load cells at specific strategic locations rather than uniform distribution. Each load cell position provides localized measurement capability, allowing the system to identify the precise location where force is applied. This localized measurement approach enables verification that force is applied at the correct position for proper connector alignment.
Solution Approach 2:
The system transitions from one-dimensional force magnitude measurement to two-dimensional measurement by incorporating spatial location information. The load plate geometry and load cell positions create a coordinate system that adds the location dimension to force measurement, enabling simultaneous verification of both magnitude and application point.
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
Ensures accurate and secure seating of electrical components by verifying the correct application of insertion and pulling forces, reducing the risk of connector disconnection during vehicle operation.
Implementation Method 1
A plurality of load cells supports the load plate and are arranged at spaced locations about the load plate such that a plugging force applied to the first electrical component retained on the load plate, via the second electrical component, in a direction perpendicular to the support surface of the load plate is transferred to the plurality of load cells
Data Source
AI summary
A test apparatus for verifying plugging force of an electrical component having sockets for receiving one or more corresponding plugs in a push fit arrangement. The test apparatus includes a load plate with a support surface orthogonal to first and a second axes. A holder retains the first electrical component on the load plate. A plurality of load cells supports the load plate at spaced locations. A plugging force applied to the first electrical component via the second electrical component is transferred to the plurality of load cells. A processor is provided for receiving load cell data corresponding to the force applied to each load cell respectively. The processor determines the magnitude of the plugging force and the location at which the plugging force is applied to the first electrical component relative to the first and second axes of the load plate.