PCB Wiring Connectors With Keyed Slots to Prevent HVAC Miswiring
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Solution Overview
Problem
Current air conditioning systems have disorganized wiring, leading to difficulties in manufacturing, assembly, and troubleshooting due to complex and randomly connected wiring harnesses, which often result in misconnection errors by field technicians.
Innovation Solution
A wiring system with a printed circuit board featuring uniquely slotted sub-receptacles and ridged connectors, ensuring each connector is receivable within only one sub-receptacle, preventing incorrect connections through distinct patterns and color coding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wiring connectors are made interchangeable to simplify assembly, then ease of manufacture is improved, but misconnection errors increase
Solution Approach 1:
The patent applies asymmetry by providing each wiring receptacle with a unique asymmetric configuration of slots and by providing each wiring connector with a corresponding unique asymmetric configuration of ridges. This asymmetric design ensures that each connector can only be properly inserted into its designated receptacle, preventing misconnection while maintaining ease of assembly through the simple plug-and-play interface.
2Reliability
If wiring connectors are made unique to prevent misconnection, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent applies local quality by making only the critical connection interface unique through asymmetric slot and ridge configurations, while keeping the rest of the wiring system standardized. The uniqueness is localized to the engagement features (slots and ridges), allowing the connectors to be differentiated without requiring complete redesign of the entire wiring harness, thus limiting complexity increase to only what is necessary for error prevention.
Data Source
AI summary
A wiring system for use in an air conditioning system comprising a printed circuit board having wiring receptacles and wiring connectors. In one aspect, at least some of the wiring receptacles comprise two or more wiring sub-receptacles, and each of the wiring sub-receptacles includes a slotted sub-receptacle connection pattern. Furthermore, the slotted sub-receptacle connection pattern of each of the wiring sub-receptacles is different from every other sub-receptacle connection pattern. Each of the wiring connectors includes a ridged connection pattern that is different from every other ridged connection pattern of the wiring connectors, such that a given wiring connector is receivable within only one of the wiring sub-receptacles. An air conditioning system and a method of manufacturing is also provided.