Connector Assembly Verification via Optical Light Detection
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Solution Overview
Problem
Conventional methods for verifying the assembly of connectors, such as Push-Click-Tug-Verify, are labor-intensive, unreliable, and costly, especially in high-volume applications like motor vehicle production, where hundreds or thousands of connections need to be made reliably.
Innovation Solution
A connector assembly system featuring a male and female connector with an indicator region on the male connector that emits a distinguishable light when not fully assembled, allowing for automated verification using light detection, reducing the need for manual labor and costly position assurance features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual verification processes like Push-Click-Tug-Verify are used to ensure connector assembly reliability, then connection reliability is improved, but labor intensity and time consumption increase significantly
Solution Approach 1:
The patent replaces manual mechanical verification (Push-Click-Tug-Verify) with an automated optical detection system. A light source illuminates the connector assembly, and a sensor detects whether light passes through a window in the housing, automatically determining if the connector is fully inserted without requiring manual tension forces.
Solution Approach 2:
The connector assembly itself provides verification information through its structural features (window in housing, light-blocking properties of the connector body). The system uses the connector's own physical characteristics to indicate assembly status, eliminating the need for separate verification tools or manual inspection.
2Reliability
If position assurance features like male tabs and female slots are incorporated into connectors to ensure proper seating, then assembly reliability is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent uses optical property changes (light transmission vs. blocking) as an indicator of assembly status. The connector housing includes a window that allows light to pass through when the connector is improperly assembled, while proper insertion causes the connector body to block the light path, providing a clear visual/光学 signal of assembly status.
Solution Approach 2:
The patent introduces light as an intermediary to transmit information about assembly status. Rather than relying on mechanical features alone, the system uses light transmission through the housing window as a mediator to indicate whether the connector is properly seated, simplifying the connector design while maintaining reliability.
3Reliability
If extensive position assurance features are added to all connectors in high-volume production, then connection reliability is improved, but manufacturing cost becomes prohibitive
Solution Approach 1:
The patent replaces complex mechanical position assurance features with a simpler optical verification system. Instead of adding multiple locking mechanisms, tabs, and slots to each connector, the system uses a light source and sensor to verify assembly, significantly reducing per-unit manufacturing cost while maintaining reliability through automated detection.
Solution Approach 2:
The patent creates an optical copy or representation of the assembly status through light transmission. The presence or absence of light blocking by the connector body provides information about assembly completeness without requiring physical copies of verification tools or complex mechanical indicators on each connector.
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
Enables efficient and reliable verification of connector assembly through automated light detection, reducing labor costs and improving the accuracy of assembly verification in high-volume production environments.
Implementation Method 1
The indicator region is configured to emit light having a component wavelength that differs substantially from light emitted by the housing of the female connector or by the background region of the male connector.
Data Source
AI summary
A connector assembly comprises a male connector and a female connector. The female connector includes a housing having an inner surface defining a cavity configured to receive the male connector. The male connector includes a housing having an outer surface configured to enable the male connector to be at least partially inserted into the cavity. The outer surface comprises a background region and an indicator region configured to emit a detectable quantity of light that is distinguishable from light emitted by the background region of the male connector and from light emitted by the housing of the female connector. The indicator region is shaped and positioned to be at least partially exposed whenever the male connector is not fully assembled into the female connector and to be completely within the housing of the female connector whenever the male connector is fully assembled into the female connector.