Electrical Connector Preassembled Sub-Module Handling
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Solution Overview
Problem
In the automotive industry, especially with the rise of autonomous driving technologies, modular electrical connectors face challenges in production due to space constraints and handling difficulties when linking sub-connectors with numerous wires, leading to inefficiencies in manufacturing.
Innovation Solution
An electrical connector design featuring preassembled modules with a component position assurance device that locks sub-modules in place, utilizing a flexible locking mechanism and handle for easy assembly and visibility, allowing for secure alignment and locking along a mating axis, while being cost-effective and easy to handle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sub-connectors are linked together in a frame to hold them in place, then the connectors are securely held and linked, but the frame cannot be handled when a lot of wires are attached on each sub connector, making the linking process impossible during manufacturing
Solution Approach 1:
The connector system is divided into separate sub-connectors (first connector housing and second connector housing) that can be handled independently. The component position assurance device is integrated with one sub-connector, allowing it to be manipulated as a single unit rather than requiring separate handling of multiple wired sub-connectors, thus resolving the handling difficulty while maintaining secure connection.
Solution Approach 2:
The component position assurance device is nested within or integrated with the first connector housing, forming a pre-assembled unit. This integration allows the assurance device to move together with the sub-connector it is attached to, eliminating the need to separately handle the assurance device when manipulating wired sub-connectors during assembly.
2Ease of operation
If a component position assurance device is integrated with the first connector housing, then handling during assembly is very easy, but the device must be prevented from being pulled off and its position must be controlled
Solution Approach 1:
The component position assurance device incorporates self-actuating locking and blocking mechanisms that automatically engage and disengage based on the assembly state. The fifth locking means automatically prevents the device from being pulled off when attached to the first connector housing, and the second blocking means automatically prevents movement in the fully assembled position, eliminating the need for additional control mechanisms.
Solution Approach 2:
The locking and blocking mechanisms are pre-configured on the component position assurance device to automatically perform their functions during the assembly process. The fifth locking means is pre-set to engage with the first connector housing, and the second blocking means is pre-positioned to interact with the first blocking means, allowing the device to self-regulate its position without external intervention.
3Object-affected harmful factors
If the component position assurance device protrudes opposite to the mating direction, then it prevents interference with electrical wires, but the device must be designed to allow easy pushing along the mating axis
Solution Approach 1:
Instead of protruding in the conventional direction (along the mating axis), the component position assurance device protrudes in the opposite direction (away from the mating direction). This inverted configuration naturally positions the device away from electrical wires that would otherwise be in the path of insertion, preventing interference while maintaining accessibility for assembly operations.
Data Source
Figure 1
Figure 2
Figure 3~4b
AI summary
An electrical connector (10) for connecting to a counter connector(500) along a mating axis (X), the electrical connector (10) comprising a first connector housing (100) comprising a terminal cavity (102), a second connector housing (200) comprising a connector cavity (202) adapted to receive the first connector housing(100), a component position assurance device (300) that locks the first connector housing to the second connector housing and a terminal (400) carried in the terminal cavity in a fully assembled position (A), wherein the first connector housing (100), the terminal cavity (102) and the second connector housing (200) are aligned along the mating axis (X), wherein the electrical connector comprises a preassembled state (P), wherein the first connector housing and the second connector housing are separated and wherein the component position assurance device is assembled to and hold at the first connector housing in a pre-locked position (PL), whereby the component position assurance device is prevented from been pulled off the first connector housing by fifth locking means, provided on the component position assurance device, cooperating with first locking means provided on the first connector housing and whereby the component position assurance device is prevented from being moved in the fully assembled position (A) by second blocking means provided on the component position assurance device, cooperating with first blocking means provided on the first connector housing, whereby the second blocking means are released by first releasing means attached in the connector cavity, when the first connector housing is inserted into the second connector housing, allowing the component position assurance device to move to the fully assembled position (A).