Motor Vehicle Connector Quality Testing via Perpendicular Force
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Solution Overview
Problem
Current methods for testing the quality and failure probability of electrical connectors in motor vehicles are inefficient, relying on empirical values and costly experimental tests that are prone to misinterpretation and high resource expenditure, with accelerated tests risking the activation of unintended degradation mechanisms.
Innovation Solution
A method using a quality testing device that applies a first force to a connector and a second perpendicular force to simulate dynamic loads, capturing electrical contact resistance and motion distance to analyze connection quality, allowing for empirical evaluation of failure probabilities under controlled conditions, including the influence of heat and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If accelerated tests with increased loads (temperature and vibration) are used to determine failure probability, then the test efficiency is improved, but the risk of triggering unintended degradation mechanisms increases
Solution Approach 1:
The patent applies parameter changes by systematically varying load parameters (force magnitude, vibration frequency, temperature) to identify the threshold at which unintended degradation mechanisms are triggered. This allows the test to remain accelerated while maintaining accuracy by stopping before the harmful threshold is reached.
Solution Approach 2:
The patent implements feedback mechanisms where the test system continuously monitors the connector performance parameters and adjusts the applied loads in real-time. When indicators of unintended degradation are detected, the test automatically reduces the load intensity, preventing misleading results while maintaining test efficiency.
2Measurement precision
If multiple test parts are required to collect valid and statistically reliable data, then the measurement precision is improved, but the loss of time and money increases
Solution Approach 1:
The patent employs dynamic testing approaches where the same test part is subjected to varying load conditions over time, allowing multiple statistical data points to be collected from a single physical sample. This eliminates the need for multiple static test parts while maintaining statistical reliability.
Solution Approach 2:
The patent implements continuous monitoring and testing protocols where the connector is subjected to prolonged cyclic loading with continuous measurement of performance parameters. This continuous action generates sufficient statistical data from a single test part, eliminating the need for multiple separate tests and reducing overall time and resource consumption.
3Measurement precision
If each contact system must be tested and evaluated separately, then the measurement precision is improved, but the device complexity and resource expenditure increase
Solution Approach 1:
The patent develops a universal testing system that can evaluate multiple contact system types using the same basic test apparatus and methodology. The system is designed with adjustable parameters and modular components that can be reconfigured to test different connector types, eliminating the need for separate specialized test equipment for each contact system.
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
This approach enables a time- and cost-efficient evaluation of connector quality, providing objective and reliable failure probability assessments by simulating real-world loads and conditions, reducing the risk of misinterpretation and resource wastage.
Implementation Method 1
A second force FM on the connector 3 is executed by a motion mechanism 14 of the quality testing device 1, wherein the second force FM is perpendicular to the first force FK, and wherein the second force FM is executed basically in a connection direction of the connector 3 and the contact element 4
Implementation Method 2
At least an electrical contact resistance R of the connection 2 is captured by a first capturing device 5 of the quality testing device 1
Implementation Method 3
a motion distance Sc of the connector 3 relative to the contact element 4 is captured by a second capturing device 6 of the quality testing device 1
Implementation Method 4
The second force FM is generated by a spring element 8 of the quality testing device 1. In particular, a spring constant CF of the spring element 8 is taken into consideration during the analyzing
Data Source
Figure 1
Figure 2
AI summary
The invention relates to a method for executing a test of a quality of a connection (2) between a connector (3) of a motor vehicle and a contact element (4) of the motor vehicle by a quality testing device (1), comprising the steps of providing a first force (FK) of the connection (2) of the connector (3) and the contact element (4); executing a second force (FM) on the connector (3) by a motion mechanism (14) of the quality testing device (1), wherein the second force (FM) is perpendicular to the first force (FK), and wherein the second force (FM) is executed basically in a connection direction of the connector (3) and the contact element (4); capturing at least an electrical contact resistance (R) of the connection (2) by a first capturing device (5) of the quality testing device (1) and capturing a motion distance (Sc) of the connector (3) relative to the contact element (4) by a second capturing device (6) of the quality testing device (1); and analyzing the quality of the connection (2) depending on the captured electrical contact resistance (R) and the captured motion distance (Sc) by an electronic computing device (7) of the quality testing device (1). Furthermore, the invention relates to a computer program product and to quality testing device (1).