Connector Mating Assurance via Acoustic Latch Detection
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Solution Overview
Problem
Existing connector mating assurance systems fail to reliably ensure proper mating of electrical connectors, especially in noisy environments like automotive assembly factories, where vibrations can cause connectors to loosen and fail, and conventional methods are costly or labor-intensive.
Innovation Solution
A connector mating assurance system using a microphone to detect the audible sound of connector latching, with an output unit processing audio signals to provide feedback to assemblers, optionally filtering background noise and comparing audio signals to templates for type differentiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical assurance tests are used to verify connector mating, then the testing process is simple, but the reliability of detection is insufficient in noisy environments
Solution Approach 1:
The patent introduces a microphone as an intermediary device to capture the acoustic signal of the latch mechanism. This mediator converts the mechanical latch event into an audible signal that can be processed and verified, providing an additional sensing modality beyond electrical testing to improve detection reliability in noisy environments.
Solution Approach 2:
The patent replaces reliance on human auditory verification with an automated acoustic detection system. The microphone captures latch sounds and the system automatically analyzes these acoustic signals to confirm proper connector mating, substituting mechanical/acoustic sensing with electronic signal processing to eliminate human error and improve consistency.
2Reliability
If a double casing system is used to verify proper mating, then mating assurance is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent implements an acoustic feedback mechanism where the microphone captures the latch sound, the system processes this audio signal to detect the characteristic click pattern, and provides confirmation of proper mating. This feedback loop verifies connector engagement without requiring complex mechanical verification structures like double casings.
Solution Approach 2:
The connector assembly process becomes self-verifying through the acoustic signature of the latch mechanism. The proper mating action automatically produces a detectable sound signal that confirms successful engagement, eliminating the need for separate verification mechanisms or complex structural designs.
3Reliability
If acoustic detection is used to verify connector mating, then detection reliability improves, but the difficulty of detecting and measuring increases due to noise filtering requirements
Solution Approach 1:
The system performs preliminary actions by capturing and analyzing the acoustic signal immediately at the moment of latch engagement. The microphone is positioned to optimize capture of the latch sound, and the system processes the audio signal in real-time to identify the characteristic click pattern before background noise can interfere, ensuring accurate detection.
Solution Approach 2:
The patent changes the detection parameter from electrical continuity to acoustic signal characteristics. By analyzing the frequency, amplitude, and temporal pattern of the latch sound, the system distinguishes the mating event from background noise. This parameter transformation enables reliable detection through audio fingerprinting of the latch mechanism.
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 proper mating of electrical connectors by enhancing audible verification, reducing errors and costs associated with secondary verification systems, and providing visual or audio feedback in noisy conditions.
Implementation Method 1
a microphone configured to be located in a vicinity of a mating zone for electrical connectors. The microphone is configured to detect an audible sound when the electrical connectors are mated.
Data Source
AI summary
A connector mating assurance system includes a microphone configured to be located in a vicinity of a mating zone for electrical connectors. The microphone is configured to detect an audible sound when the electrical connectors are mated. An output unit is connected to the microphone and receives audio signals from the microphone. The output unit processes the audio signals for mating assurance. The output unit may provide feedback to an assembler based on the audio signals. The output unit may determine if the electrical connectors are properly mated based on the audio signals. The microphone may be held by the assembler proximate to the assembler's hand when assembling the electrical connectors.