Connector Position Assurance With Scannable Lock-State Indicia

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Solution Overview

Problem

Existing connector systems require human verification to ensure proper mating and securing, which is prone to errors and reduces efficiency, especially in critical applications like automotive systems.

Innovation Solution

A mechanical and electrical connector system with a readable and recordable indicia that allows for automated detection of installation states, reducing the need for human verification and enhancing precision.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If human verification is used to inspect connector assemblies, then installation accuracy can be maintained, but productivity decreases and errors increase

Engineering Contradiction:

Improveinstallation verification accuracyVSAvoidinstallation efficiency

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent replaces the mechanical human verification process with an automated optical scanning system. The scanner reads indicia on connector assemblies to automatically verify installation states, eliminating the need for manual inspection while maintaining high accuracy and improving productivity through automation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connector assembly includes self-identifying indicia that automatically provide verification information when scanned. The system serves itself by encoding installation states in machine-readable format, eliminating the need for external human judgment and enabling automated verification.

Inventive Principle:

Principle #25Self-service

2Reliability

If multiple human inspections are conducted to reduce errors, then reliability improves, but loss of time increases

Engineering Contradiction:

Improveconnection accuracyVSAvoidinspection time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The indicia are pre-configured on the connector assembly to encode installation state information in advance. This preliminary encoding allows for rapid verification during inspection, eliminating the need for multiple time-consuming manual checks while maintaining high reliability through automated reading of pre-prepared information.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Multiple manual inspections are replaced by a single automated scanning operation. The optical scanner rapidly reads the pre-encoded indicia to verify installation states, achieving the same reliability as multiple inspections but in a fraction of the time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If human verification is used to determine proper mating, then connection reliability can be ensured, but device complexity increases

Engineering Contradiction:

Improveconnector mating accuracyVSAvoidverification system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The verification function is extracted from the human operator and embedded directly into the connector assembly through machine-readable indicia. This extraction simplifies the overall system by replacing complex human judgment processes with simple machine-readable codes that can be rapidly scanned and verified.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The installation state information is copied into machine-readable indicia on the connector assembly. This copying allows the verification system to read and process installation states automatically without requiring complex human analysis, reducing system complexity while maintaining reliability.

Inventive Principle:

Principle #26Copying

4Productivity

If automated scanning system is implemented, then productivity increases, but device complexity increases

Engineering Contradiction:

Improveinstallation verification speedVSAvoidrecording system complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The scanner is designed to read multiple types of indicia (barcodes, QR codes, data matrices) and interpret various installation states through a single unified system. This multi-functionality allows the scanning system to handle diverse verification requirements without proportionally increasing complexity, maintaining high productivity across different connector types.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12237610B2Connector recording system with readable and recordable indicia

Publication Date: 2025.02.25 EATON INTELLIGENT POWER LTD

AI summary

The invention generally provides a connector recording system or platform that includes a recording system designed to interact with a connector system to read an indicia and then transfer, store, and display information associated with the positioning of the connector system in the installed component or device. The connector system includes a male housing assembly, a female housing assembly coupled to the male housing assembly in a connected state, and a connector position assurance assembly with the indicia and a locking member that is movable between locked and unlocked positions. In the locked position, the locking member secures the male housing assembly to the female housing assembly and the indicia can be read by the scanner to signal that the connector position assurance assembly is in the locked position. In the unlocked position, the indicia is in a state that does not allow the scanner to obtain information from the indicia.