Safety Restraint Connector Shunt Release for Easier Testing
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Solution Overview
Problem
Existing electrical connectors for safety restraint systems in motor vehicles face increased complexity and production costs due to integrated shunt devices, and require inconvenient testing procedures.
Innovation Solution
An electrical connector design featuring a separate shunt and connector position assurance (CPA) device, where the CPA device moves to lift the shunt from a short-circuiting position across the terminals, allowing for unimpeded signal transmission and simplifying testing by external mechanical actuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an integrated shunt device is provided in the electrical terminals, then the electrical connector prevents unintended electrical signal conveyance during mating and installation, but the complexity and production cost of the electrical terminals increase
Solution Approach 1:
The shunt device is separated from the electrical terminals into an independent component. The shunt comprises two shunt arms and a shunt bridge, which are distinct from the terminals. This segmentation reduces the complexity of the terminals while maintaining the safety function through the separate shunt mechanism that is mechanically actuated by the CPA device.
2Reliability
If an integrated shunt device is manufactured in one piece with the electrical terminals in expensive corrosion-resistant and conductive materials, then the shunt provides reliable short-circuiting protection, but the production cost increases significantly
Solution Approach 1:
The shunt is manufactured as a separate component from the electrical terminals, allowing for optimized material selection and manufacturing processes. This separation enables the terminals to be produced using expensive corrosion-resistant and conductive materials only where needed, while the shunt can be manufactured more economically, thereby reducing overall production costs while maintaining reliability.
3Measurement precision
If the CPA device is moved into a locked position by means of a dedicated counterpart to lift the short-circuiting for testing, then the electrical conductivity of the connector can be tested, but the testing procedure becomes inconvenient and complex
Solution Approach 1:
The CPA device is designed to be directly actuated by the testing device without requiring intermediate counterparts. The testing device can directly move the CPA device between unlocked and locked positions, enabling convenient testing of the electrical connector's conductivity. This self-service design eliminates the need for complex dedicated counterparts and simplifies the testing procedure.
Data Source
AI summary
An electrical connector for a safety restraint system of a motor vehicle comprises a housing, a pair of electrical terminals, a shunt and a connector position assurance (CPA) device. The housing includes a first end and a second end, the second end extending in a mating direction of the connector. Each of the electrical terminals traverses the housing from the first end to the second end. The shunt is adapted to short-circuit the pair of electrical terminals, and comprises two shunt arms each having a contact portion and a linking portion, and a shunt bridge linking the linking portions of the shunt arms. The CPA device is moveably arranged in the housing between an unlocked position and a locked position. In the locked position the CPA device lifts the shunt from a short-circuiting position across the terminals.