Plug Gauge for Automotive Electrical Connector Verification
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Solution Overview
Problem
The existing methods for connecting measuring devices to electrical lines in motor vehicles often result in damage due to incorrect plug sizing, wobbling, and potential short circuits, leading to costly and time-consuming replacements.
Innovation Solution
A plug gauge system with a socket housing and plug contact designed to match the exact cross-sectional geometry of the line plug and socket, ensuring a secure, damage-free connection through precise fitting and additional contact surfaces to prevent movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a measuring device contact is used that is too large or incorrectly shaped, then the measuring device can be connected to the electrical line, but the line socket is damaged irreparably
Solution Approach 1:
The patent applies preliminary action by providing a gauge element that is inserted into the line socket before the actual measuring device connection. This gauge element preliminarily tests the compatibility between the plug contact and socket opening, preventing damage before it occurs. The gauge element's cross-section corresponds to the plug contact's cross-section, allowing it to verify proper fit beforehand.
Solution Approach 2:
The gauge element serves as an intermediary between the measuring device and the line socket. It mediates the connection process by first engaging with the line socket to verify compatibility, then allowing the actual measuring device to connect safely. This intermediary prevents direct damage between the measuring device and the vulnerable line socket.
2Adaptability or versatility
If the measuring device is connected via cables, then the measuring device can be positioned flexibly, but the cable socket is widened or the cable plug is bent due to vibrations
Solution Approach 1:
The gauge element preliminarily stabilizes the connection by fitting precisely into the line socket and receiving the plug contact. This preliminary stabilization prevents vibration-induced damage before the measuring device is fully connected via cables, protecting the cable socket and plug from widening or bending.
3Ease of operation
If the measuring device terminal slips on the line contact, then the measuring device can maintain contact, but a short circuit with another line contact occurs
Solution Approach 1:
The gauge element preliminarily verifies the correct positioning and fit of the plug contact within the line socket. By ensuring proper alignment before the measuring device connects, it prevents terminal slippage that could cause short circuits with other line contacts.
Solution Approach 2:
The gauge element acts as an intermediary that ensures proper positioning of the plug contact. It mediates the connection to prevent slippage and the subsequent harmful effect of short circuits, while still allowing electrical contact to be maintained.
4Adaptability or versatility
If multiple standardized line contacts with similar appearances are used, then the electrical system can be standardized, but the line contacts are difficult to distinguish visually
Solution Approach 1:
The patent applies local quality by making the gauge element itself distinctive rather than relying on visual distinction of the line contacts. Each gauge element can have specific local characteristics (cross-sectional shape, dimensions) that correspond to specific line contact types, enabling correct identification through the gauge-fitting process rather than visual inspection.
Data Source
Figure 1
AI summary
The device (1) has a plug unit (3) with a plug contact (13) electrically contactable with a measuring device e.g. continuity tester and voltmeter. A socket unit (4) with a socket housing (16) is electrically contactable with the measuring device. Cross-section of an aperture (15) in the socket housing is formed corresponding to cross-section of the plug contact. The arrangement of the aperture in the socket housing enables access to a socket contact within the housing and/or a connection opening is formed in the housing. The socket unit has the socket contact corresponding to the plug contact. An independent claim is also included for a plug device set.