Electrical Connector Position Sensing for Vibration Separation
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Solution Overview
Problem
Existing electrical connectors in vehicles experience separation of male and female terminals due to vibration, leading to loss of electrical connection, which is not effectively monitored or addressed.
Innovation Solution
Incorporation of sensors within the electrical connector housings to monitor the relative position of terminal housings, using various types such as pressure sensors and electrical contacts to detect partial separation and alert a controller, which can disable or reduce vehicle functions when a full connection is not maintained.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are added to monitor connector position, then reliability of electrical connection is improved, but device complexity increases
Solution Approach 1:
The monitoring function is merged with the existing connector housing structure. Sensors are integrated into the housing components that already exist for mechanical connection, combining the structural and monitoring functions into a unified system rather than adding separate monitoring equipment.
Solution Approach 2:
The connector system monitors its own position and connection status using integrated sensors, enabling self-diagnosis and self-monitoring capabilities. The system automatically detects separation conditions and can trigger alerts or protective actions without external monitoring equipment.
2Measurement precision
If multiple sensors are used to detect partial separation, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The monitoring function is divided into multiple sensor positions along the connector interface. By placing sensors at different locations (e.g., front, middle, rear positions), the system can detect partial separations at various stages, providing precise measurement of connection status through segmented monitoring points.
Solution Approach 2:
The system uses multiple sensors to detect partial separation conditions before complete disconnection occurs. This excessive monitoring approach ensures that even minor separations are detected, providing early warning capability and enabling preventive actions before total connection loss.
Data Source
AI summary
An electrical connector is provided. The electrical connector includes a first housing having an outer surface and a second housing configured to receive the first housing, wherein the second housing includes an inner surface configured to contact the outer surface of the first housing. The electrical connector also includes a plurality of sensors configured to monitor a contact between the inner surface and the outer surface and a controller in communication with the plurality of sensors, wherein the controller is configured to determine a position of the first housing relative to the second housing.