Optical Assurance Cap for Fluid Connector Seating Verification
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Solution Overview
Problem
Current fluid connectors in automotive systems often suffer from incomplete seating of tubular connectors due to reliance on visual witness beads and audible clicks, which are not always reliable, leading to potential leak paths during pressurization.
Innovation Solution
An optical assurance cap with varying light absorption coefficients is used in conjunction with a tester tool containing a light source and sensor to ensure proper seating by detecting light deflection through the cap's sections, preventing leaks by confirming full seating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If visual witness beads and audible clicks are used to indicate proper seating, then the assembly process is simple, but the reliability of detecting proper seating is insufficient
Solution Approach 1:
The assurance cap utilizes light absorption coefficient changes (analogous to color changes) by incorporating sections with different light absorption coefficients that create distinct optical signatures when properly seated, allowing reliable detection of seating status through optical measurement
Solution Approach 2:
The patent replaces the mechanical/visual detection methods (witness beads and audible clicks) with an optical detection system using light sources and sensors to measure light absorption, providing more reliable and objective seating verification
2Strength
If the assurance cap is made opaque for durability, then the cap strength is improved, but the ability to detect light deflection for seating verification is reduced
Solution Approach 1:
The assurance cap incorporates sections with different light absorption coefficients in specific locations, allowing certain areas to be optically active for detection while maintaining overall structural integrity and strength through the cap design
3Measurement precision
If multiple sections with different light absorption coefficients are added to the cap, then the precision of seating detection is improved, but the manufacturing complexity increases
Solution Approach 1:
The assurance cap is divided into multiple sections with different light absorption coefficients, each section contributing to the overall optical signature that enables precise detection of proper seating through systematic optical measurement
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 optical assurance cap effectively prevents leaks by ensuring the tubular connector is fully seated within the fluid connector, providing a reliable method for users to verify proper assembly and reducing the risk of leaks during system pressurization.
Implementation Method 1
an optical assurance cap including a second through-bore, a first section having a first light absorption coefficient, a second section having a second light absorption coefficient, and a third section having a third light absorption coefficient
Data Source
AI summary
A fluid connector assembly, including a fluid connector including a first through-bore, an optical assurance cap arranged on said fluid connector, said optical assurance cap including a second through-bore, a tubular connector arranged in said first through-bore and secured to said fluid connector, and a tester tool, including a channel, a light source, and a light sensor, said light source and said light sensor axially displaced from one another, wherein said optical assurance cap is arranged in said channel of said tester tool.