PCB Wiring Receptacle Layout to Prevent AC Misconnections
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Solution Overview
Problem
Current air conditioning systems have disorganized wiring, leading to difficulties in manufacturing, assembly, and troubleshooting due to interchangeable wiring connectors, which often result in misconnections and malfunctions.
Innovation Solution
A wiring system with a printed circuit board featuring uniquely configured slotted sub-receptacles and ridged connectors, ensuring each connector is receivable within only one sub-receptacle, thereby preventing incorrect connections and enhancing organization and accessibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If interchangeable wiring connectors are used in air conditioning systems, then ease of assembly is improved, but connection reliability deteriorates due to misconnections and servicing errors
Solution Approach 1:
The patent applies asymmetry by designing wiring receptacles with unique slot patterns (e.g., slots at different positions, orientations, and configurations) that correspond to specific ridged connectors. This asymmetric design ensures that each connector can only be inserted into its designated receptacle, preventing misconnections while maintaining ease of assembly through intuitive alignment.
Solution Approach 2:
The patent implements local quality by giving each wiring receptacle a distinct slot pattern configuration tailored to its specific function and location. Rather than using uniform connectors throughout the system, each receptacle has customized slot arrangements (e.g., slots at different angles, positions, or numbers) that match only the intended connector, thereby ensuring connection reliability without compromising assembly ease.
2Device complexity
If disorganized wiring is used in air conditioning systems, then device complexity is reduced, but troubleshooting difficulty increases
Solution Approach 1:
The patent applies segmentation by dividing the wiring system into distinct, organized groups where each wiring receptacle and its corresponding connector form a dedicated connection unit. The unique slot patterns create natural segmentation that groups related connections together, making the wiring system more organized and easier to troubleshoot without significantly increasing overall device complexity.
3Reliability
If unique slot patterns are used in wiring receptacles, then connection reliability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The patent applies preliminary action by pre-configuring the unique slot patterns into the wiring receptacles during the board design and manufacturing phase. These patterns are built-in and fixed, eliminating the need for field technicians to configure them during assembly or servicing. This preliminary configuration ensures connection reliability while allowing standard manufacturing tolerances to be used.
Data Source
AI summary
A wiring system for use in an air conditioning system comprising a printed circuit board having a perimeter and wiring receptacles located proximate the perimeter 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.