Electrical Connector Lock With Visual Assembly Confirmation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing connection devices for electric vehicles lack a visual confirmation of proper assembly, making it difficult to ensure reliable electrical connections, especially in high-volume manufacturing and automatic assembly chains.
Innovation Solution
A connection device featuring a lock mechanism with arms that deviate to close on notches of an electric driver, providing a visual locking witness in the form of a QR code that is only exposed when the connection is secure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple clipping connection device is used to assemble a busbar to a terminal, then the ease of manufacture is improved, but the ability to detect proper assembly is worsened
Solution Approach 1:
The patent applies visual indicators (patterns such as QR codes, barcodes, or colored patterns) on the lock arms that change their visibility or configuration based on the locking state. When the lock arms are properly spaced indicating correct assembly, the patterns become fully visible or form a recognizable code. This allows automatic optical detection systems to verify proper assembly without adding mechanical complexity to the connection device itself.
2Device complexity
If no visual indicator is provided on the connection device, then the device complexity is reduced, but the reliability of connection confirmation is worsened
Solution Approach 1:
The patent introduces visual patterns (QR codes, barcodes, or colored indicators) as an intermediary element on the lock arms that mediates between the mechanical locking state and the detection system. These patterns do not affect the mechanical function but provide an optical interface that allows remote, automatic verification of connection status, thereby enhancing reliability without complicating the core mechanical connection mechanism.
3Measurement precision
If manual inspection of connections is required, then the measurement precision can be maintained, but the productivity is reduced
Solution Approach 1:
The patent replaces manual visual inspection with automatic optical detection systems that read the patterns (QR codes, barcodes) on the lock arms. This substitution allows rapid, automated verification of connection status without requiring human operators to manually examine each connection, thereby maintaining measurement precision while dramatically increasing productivity in high-volume manufacturing environments.
Data Source
Figure 1~3
Figure 4A~4B
Figure 4C~4D
AI summary
The invention relates to a device (100) for connecting an electrical conductor (2) to an electrical connector (1), the electrical conductor (2) being provided with a pair of notches. The device (100) comprises a lock formed of two arms (4a, 4b) that are able to be moved away from one another and to close back over the second element in order to be accommodated in the notches thereof and to place the lock in a locking configuration. The device comprises a visual locking indicator (5) formed of at least one pattern (5a, 5b). The visual locking indicator (5) is entirely exposed only when the lock is in the locking configuration.