Deformable CPA Lock for Engine Harness Connector Reliability
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Solution Overview
Problem
Existing connector position assurance locks for engine wiring harnesses are unreliable in maintaining the lever latch in the connected position, leading to inadvertent disengagement of connectors.
Innovation Solution
A Connector Position Assurance (CPA) lock with a deformable lock body and flexible feet that engage with the connector body, allowing the lever latch to pivot over the lock body and be captured in a locked position, preventing unintended disengagement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional CPA lock is used to prevent inadvertent disengagement, then connector reliability is improved, but the device complexity increases and may interfere with lever latch operation
Solution Approach 1:
The CPA lock is divided into distinct functional segments: a lock body for structural support, a deformable top surface for lever latch interaction, and flexible feet for connector engagement. This segmentation allows each component to perform its specific function independently while reducing overall complexity.
Solution Approach 2:
The lock body incorporates dynamic elements including a deformable top surface that flexes to accommodate lever latch movement, and flexible feet that adapt to connector positioning. These dynamic features enable the lock to maintain reliability while adapting to operational requirements without adding fixed complexity.
2Stability of the object's composition
If the CPA lock structure is made more robust to ensure reliable locking, then connection stability is improved, but the ease of operation deteriorates due to difficulty in deformation
Solution Approach 1:
Different regions of the lock body have different mechanical properties: the lock body itself is rigid for stability, while the top surface is deformable for ease of operation. The flexible feet provide localized compliance for connector engagement. This local differentiation of material properties resolves the contradiction between stability and operability.
Solution Approach 2:
The lock design utilizes parameter changes in material stiffness across different components. The rigid lock body maintains connection stability, while the deformable top surface and flexible feet change their effective stiffness during operation to allow easy lever latch pivoting and connector engagement.
3Strength
If the CPA lock uses rigid feet for strong connector engagement, then locking strength is improved, but the adaptability to different connector positions deteriorates
Solution Approach 1:
The CPA lock employs flexible feet made of elastomeric material that can deform to adapt to different connector positions while maintaining sufficient engagement strength. The flexible nature allows the feet to conform to variations in connector positioning without compromising the locking strength.
4Ease of manufacture
If the CPA lock design is simplified for ease of manufacture, then manufacturing cost is reduced, but the reliability of maintaining lever latch position deteriorates
Solution Approach 1:
The CPA lock combines multiple functions into a single integrated lock body component: structural support, lever latch engagement surface, and connector feet. This merging simplifies manufacturing by reducing the number of separate parts while maintaining reliability through the carefully designed deformable top surface that ensures proper lever latch positioning.
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 CPA lock effectively maintains the connector in a connected state, ensuring reliable electrical connections and easy disengagement when needed, with a design that is tool-free and compatible with various connector types.
Implementation Method 1
Two flexible feet extend from the side walls of the lock body, and extend rearward from the rear face to engage with the connector
Implementation Method 2
The CPA lock has a body with a deformable surface and a foot extending from the lock body... deforming the lock body to permit the lever latch to pivot over a top surface of the lock body... the lever latch is captured in the pivoted position by the un-deformed foot
Data Source
AI summary
A Connector Position Assurance (CPA) lock (10) for an engine wiring harness connector (12) having a connector body (14) and a lever latch (30) pivotal with respect to the connector body includes a lock body (34). A foot (52) extends from the lock body (34) and engages the connector (12) to fix the position of the lock body relative to the connector. The lock body (34) captures the lever latch (30) and prevents the pivoting of the lever latch with respect to the connector body (40) unless the foot (52) is deformed.