2D Laser Sensor for Connector Engagement Verification
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Solution Overview
Problem
Existing methods for verifying the complete engagement of electrical connectors are inefficient, particularly in inaccessible locations within complex vehicles, and current test devices are costly, complex, or prone to inaccurate results in noisy environments.
Innovation Solution
A 2D scanning laser sensor system that generates profile data of joined work pieces, compares it with a reference profile, and outputs a signal indicating complete or incomplete engagement, allowing for precise detection of connector engagement states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual pull/push forces are applied to test connector engagement, then engagement completeness can be verified, but the test becomes difficult or impossible when connectors are located in inaccessible positions
Solution Approach 1:
The patent replaces the manual mechanical pull/push test with an optical measurement system using a laser sensor. The laser sensor non-contactically measures the position and engagement state of connectors, eliminating the need for physical contact or access to the connector interface, thereby solving the accessibility problem while maintaining verification reliability
Solution Approach 2:
The patent introduces a laser sensor as an intermediary measurement device between the operator and the connector. This intermediary enables indirect measurement of engagement status through optical means, allowing verification of connectors in locations that are physically inaccessible to manual testing
2Reliability
If electrical power is applied to test circuit connectivity, then functional operation can be verified, but additional problems arise from needing special testing devices and the inability to repair covered connections
Solution Approach 1:
The patent replaces electrical power-based functional testing with optical measurement. Instead of applying electrical power and using complex testing devices to verify circuit operation, the laser sensor optically measures connector engagement position, providing verification without the complexity of electrical testing equipment and without requiring circuit activation
Solution Approach 2:
The patent creates an optical copy or representation of the connector engagement state through laser measurement. Rather than activating the actual circuit to test functionality, the system creates a measurement model of the engagement position that indicates whether proper connection has occurred, avoiding the need for complex electrical testing
3Measurement precision
If audible click noise is captured to verify connector engagement, then engagement state can be detected, but accurate detection is impossible in noisy vehicle assembly environments
Solution Approach 1:
The patent replaces acoustic detection with optical measurement. Instead of capturing and analyzing audible click noise that is obscured by environmental sounds in the assembly environment, the laser sensor directly measures the physical position and engagement state of the connector, providing precise detection that is immune to acoustic interference
Solution Approach 2:
The patent changes the measurement parameter from acoustic (click noise) to optical (laser reflection/position). This parameter change eliminates sensitivity to environmental noise while maintaining the ability to detect engagement state, as optical measurements are not affected by the acoustic environment in the same way acoustic measurements are
4Reliability
If elaborate wiring harness testers are connected to verify all harness connection points, then complete connectivity can be ensured, but the testers are costly and interfere with assembly operations
Solution Approach 1:
The patent replaces complex electrical harness testers with a simple optical laser sensor system. Instead of connecting elaborate testing equipment to verify electrical connectivity at all harness points, the laser sensor optically monitors connector engagement positions, providing verification with a much simpler, less intrusive device that does not interfere with assembly operations
Solution Approach 2:
The patent creates an optical measurement model of connector engagement that substitutes for comprehensive electrical connectivity testing. By measuring the physical engagement state of connectors, the system creates a proxy indication of harness connectivity without requiring complex electrical testing equipment or interruption of assembly flow
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
Provides a reliable, inexpensive, and accurate method to verify the complete engagement of electrical connectors, reducing assembly time and improving quality control by offering clear, actionable feedback on connector states.
Implementation Method 1
A 2D scanning laser sensor generating an output signal representative of a scanned dimensional profile of the two engaged work pieces
Data Source
AI summary
An apparatus and method for measuring the engagement state of two mating work pieces, such as two parts of an electrical connector, includes a 2D scanning profile laser sensor. The laser sensor is located in a measurement position relative to the work pieces being scanned. The laser generates a two axis surface profile of the joined work pieces. The measured surface profile is compared by a controller with a reference surface profile to determine complete or non-complete engagement of the work pieces.