Optical Wire Harness Connectors for Corrosion-Resistant Motor Signals
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Solution Overview
Problem
Conventional spreader systems for materials like rock salt face operational failures due to corrosion of copper communication terminals in the wire harness, leading to signal loss and connectivity issues when exposed to weather elements.
Innovation Solution
The use of optical terminals, such as LED and photodiode pairs, replaces copper communication terminals to establish digital optical connections between the controller and motors, reducing the risk of corrosion and ensuring reliable signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper communication terminals are used in the wire harness, then electrical connectivity is established, but corrosion occurs due to exposure to weather elements (moisture, salt, sand)
Solution Approach 1:
The patent replaces electrical/copper-based communication terminals with an optical communication system using LEDs and photodetectors. This substitution eliminates the corrosion problem inherent in copper terminals by using light-based communication instead of electrical signals through metal conductors, thereby maintaining reliability while removing the harmful effect of corrosion.
Solution Approach 2:
The patent changes the fundamental parameter of signal transmission from electrical signals through copper conductors to optical signals through light-emitting diodes and photodetectors. This parameter change transforms the communication medium from a metal-based electrical system to a light-based system, which is inherently resistant to corrosion from weather elements.
2Reliability
If copper terminals are used for power and communication, then electrical connections are established, but signal loss occurs when terminals corrode
Solution Approach 1:
The patent substitutes the copper terminal electrical connection system with an optical communication system using LEDs and photodetectors. This replacement prevents signal loss by eliminating the corrosion mechanism that degrades copper terminals, ensuring reliable control signal transmission from the controller to the motors without information loss.
3Object-affected harmful factors
If optical terminals (LED/photodiode pairs) are used instead of copper terminals, then corrosion resistance is improved, but device complexity increases
Solution Approach 1:
The patent merges the LED light source and photodetector receiver into a single integrated connector assembly. By combining these optical components into one unit that replaces the traditional copper terminal, the design reduces overall system complexity despite using advanced optical technology. The merged connector maintains electrical power connections while adding optical communication capability in a unified structure.
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
This solution provides a corrosion-resistant signal connection that maintains operational reliability by transmitting control signals as modulated light, reducing the risk of signal loss and extending the lifespan of the spreader system.
Implementation Method 1
The LED communications terminal includes a light-emitting diode that emits modulated light corresponding to an electrical waveform of the control signal from the control system.
Implementation Method 2
The photodiode of the receiver terminal receives the modulated light and converts it back into the electrical waveform of the control signal that is received at the motor and used to control the motor.
Data Source
AI summary
A wire harness includes a first connector portion that matingly connects to a second connector portion. A power cable carries electrical power from a power supply to one or more motors, and includes power segments connecting the first connector portion and the power supply, and the second connector portion and the motor. Power terminals are received within the first and second connector portions, for establishing an electrical connection between the power segments. One or more communication cables carry control signals from a control system to the motor(s) and include communication segments connecting the first connector portion and the control system and the second connector portion and the motors. Optical terminals are received within the first and second connector portions for each communication cable, for establishing a digital optical connection between each of first and second communication segments.