Connector Position Assurance Device for Vibration Resistance
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Solution Overview
Problem
Connectors, especially those on internal combustion engines, fail due to excessive relative movement caused by high vibrations and high temperatures, leading to increased failure rates and requiring higher insertion forces with non-standard, costly housings.
Innovation Solution
A connector design with a reduced spacing between components, utilizing a connector-position-assurance device and terminal-lock ribs to apply retention and compressive forces, minimizing movement and maintaining reliability without increasing insertion force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard automotive connector systems are used, then insertion force is low, but reliability is poor due to excessive relative movement under high vibration
Solution Approach 1:
The CPA device is pre-positioned in the housing before connector assembly, establishing a predetermined retention force on the terminal lock. This preliminary action ensures that when vibration occurs, the terminal lock is already constrained within a controlled clearance (less than 0.1mm) from the housing, preventing excessive relative movement without requiring high insertion forces during assembly
Solution Approach 2:
The CPA device acts as an intermediary mechanism between the housing and the terminal lock. It provides a controlled retention force that mediates the interaction between these components, maintaining a precise clearance relationship that prevents harmful vibration-induced movement while avoiding the need for high contact forces in the electrical terminals
2Reliability
If high contact force electrical terminals with non-standard housings are used, then reliability is improved, but device complexity and cost increase
Solution Approach 1:
The CPA device performs multiple functions within a single component: it provides retention force on the terminal lock, maintains the predetermined clearance relationship, and prevents excessive relative movement under vibration. This multi-functionality eliminates the need for complex non-standard housings or multiple separate retention mechanisms, achieving high reliability with a standard housing design
Solution Approach 2:
The invention changes the key parameter from high contact force in electrical terminals to a controlled retention force applied by the CPA device to the terminal lock. This parameter change allows the use of standard electrical terminals with standard housings while achieving the same vibration resistance through a different mechanical approach
3Reliability
If high contact force electrical terminals are used, then resistance to vibration is improved, but insertion force increases
Solution Approach 1:
The CPA device is pre-assembled in the housing to establish the retention force on the terminal lock before the electrical terminals are inserted. This preliminary positioning ensures that the terminal lock is already constrained within less than 0.1mm clearance from the housing, so that when electrical terminals are inserted, they do not need to overcome large clearance gaps, reducing insertion force while maintaining vibration resistance
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
The solution effectively reduces component movement and enhances reliability in high-vibration environments while maintaining low insertion forces, improving connector durability and performance.
Implementation Method 1
The retention-force deflects the connector-latch thereby applying the retention-force to the first-housing
Implementation Method 2
The plurality of ribs contact the plurality of electrical-terminals through the apertures, thereby applying a compressive-force to the plurality of electrical-terminals
Data Source
AI summary
A connector includes a first-housing and a second-housing. The first-housing includes a connector-lock. The second-housing is configured to receive the first-housing and includes a connector-latch configured to removably retain the connector-lock when the first-housing is mated with the second-housing. The second-housing includes a connector-position-assurance (CPA)-device slidably mounted to the second-housing and movable from a disengaged-position to an engaged-position. The CPA-device applies a retention-force to the connector-latch. The retention-force deflects the connector-latch thereby applying the retention-force to the first-housing when the first-housing is mated with the second-housing and the CPA-device is in the engaged-position.