High Voltage Connector Assembly With Mating Verification Mark
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Solution Overview
Problem
In high voltage battery systems of vehicles, incomplete connections of HV connectors due to operator error can lead to structural misalignment, potentially causing faults during vehicle operation, and existing methods for ensuring proper mating are time-consuming and unreliable.
Innovation Solution
A high voltage connector assembly featuring a male and female connector with identification marks that are electronically readable only when fully mated, using QR codes or bar codes, which prevent access to the mark unless fully engaged, and an external device can scan these marks to confirm proper mating and detect faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mechanical fastening methods are used for HV connectors, then structural alignment can be achieved, but the connection process becomes time-consuming and operator error can still cause incomplete mating
Solution Approach 1:
The patent replaces traditional mechanical fastening verification with an optical/electronic identification system. Optical sensors or cameras detect the identification mark (QR code, barcode, or visual indicator) to automatically verify connector mating status, substituting manual mechanical inspection with automated optical detection that is both faster and more reliable.
Solution Approach 2:
The system provides immediate feedback through optical sensors that detect whether the identification mark is properly visible and aligned. This feedback mechanism confirms complete mating in real-time, allowing operators to immediately verify correct connection without time-consuming manual checks or risking incomplete mating due to human error.
2Measurement precision
If manual inspection methods are used to verify connector mating, then proper alignment can be confirmed, but the process is time-consuming and prone to human error
Solution Approach 1:
Manual visual inspection is replaced with automated optical sensors or cameras that precisely detect the identification mark's presence and alignment. This electronic detection system provides superior measurement precision compared to human eyes while operating much faster, eliminating both the time loss and potential for human error in verification.
Solution Approach 2:
The identification mark serves as a visual copy or representation of the connector's mating status. By detecting this mark through optical sensors, the system creates an electronic copy of the physical connection state, enabling rapid and accurate verification without requiring time-consuming manual inspection of the actual mechanical connection.
3Extent of automation
If identification marks are made accessible during assembly, then monitoring can be performed, but unauthorized access or premature scanning may occur
Solution Approach 1:
The identification mark is positioned in a specific localized area that is only accessible or visible when the connector is in its final mated position. This spatial restriction ensures that monitoring can occur automatically through sensors in that location, while premature or unauthorized access is prevented because the mark simply cannot be reached or scanned before proper assembly.
Solution Approach 2:
The identification mark acts as an intermediary element that mediates between the physical connector assembly and the monitoring system. By placing the mark in a location accessible only through proper assembly, it serves as a controlled interface that enables automated monitoring while preventing direct unauthorized access to the connector's internal components or electrical contacts.
Data Source
AI summary
A high voltage connector assembly includes a first connector and a second connector. The first connector has two tiers of pins and a first portion of an identification mark. The second connector includes a second portion of the mark and has two tiers of wells sized to engage the pins without other mechanical fasteners. The first and second portions are arranged on the connectors such that the portions are aligned to define the mark when the connectors are completely engaged. The mark may include one or more electronically readable indicators identifying each of the first and second connectors. The connectors may electrically connect a first vehicle component in communication with the pins and a second vehicle component in communication with the wells when the connectors are completely engaged.