Modular Connector Carrier for Self-Aligning ECU Harness Assembly
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Solution Overview
Problem
The installation of vehicle wiring harnesses is complex and requires significant effort due to the difficulty in reliably coupling connectors between cables and other components, necessitating a more efficient and cost-effective electrical connection system.
Innovation Solution
A self-aligning modular electrical connector system with a common carrier and connector carriers that securely retain and move connectors to mate with an Electronic Control Unit (ECU), allowing for robotic installation and simplified cable management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional wiring harness installation methods are used, then connectors can be coupled to establish electrical connections, but the installation process becomes complex and requires significant effort
Solution Approach 1:
The system divides the wiring harness into modular segments with pre-assembled connector carriers that can be independently handled and installed. Each connector carrier contains organized cable bundles with connectors ready for mating, allowing incremental installation rather than handling entire complex harnesses at once.
Solution Approach 2:
The connector carrier acts as an intermediary device that pre-organizes multiple cables and connectors into a single manageable unit. This intermediary structure simplifies the installation process by replacing multiple individual connector couplings with a single carrier installation operation.
2Reliability
If connectors are manually coupled to establish reliable electrical connections, then connection reliability can be achieved, but installation time and cost increase
Solution Approach 1:
The connector carriers are pre-assembled with cables and connectors properly positioned and aligned before installation. This preliminary preparation ensures that when the carrier is installed, the electrical connections are automatically established with correct alignment, eliminating the need for time-consuming manual adjustment while maintaining connection reliability.
Solution Approach 2:
Multiple individual connector coupling operations are merged into a single carrier installation operation. By combining several cables and connectors into one integrated carrier unit, the system achieves the same reliable electrical connections that would require multiple separate manual operations, thereby reducing total installation time.
3Productivity
If traditional wiring harness systems are used, then electrical connections can be established, but the installation process requires significant effort and expense
Solution Approach 1:
The wiring harness system is segmented into standardized modular units that can be quickly installed in sequence. This segmentation allows installation teams to work efficiently on discrete sections rather than managing complex entire harnesses, improving overall productivity while maintaining ease of operation through standardized interfaces.
Solution Approach 2:
The connector carriers are designed with universal features that allow them to be installed using standardized procedures and tools across different applications. This multi-functionality enables the same installation process to be reused repeatedly, increasing productivity without sacrificing ease of operation.
Data Source
Figure 1
Figure 2A
Figure 2B~3A
AI summary
An electrical connection system is described which includes a common carrier. The common carrier includes a main channel configured to retain a cable bundle and a plurality of side channels that facilitate coupling of at least some cables of the cable bundle to an electronic control unit (ECU). The side channels are configured to retain a connector carrier configured to carry a pair of connectors slidable in each side channel between a pre-staged position in preparation for mating and a mated position which mates terminals carried by the pair of connectors and locks the pair of connectors to the ECU.