Plug Verification Element for Secure Connection Checking
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Solution Overview
Problem
Existing plug-in connections in the automobile industry cannot be reliably checked for secure connection state after assembly, as the connection state can only be verified if the plug-in connection is available for inspection, making it impossible to ensure all units are correctly connected at the assembly station.
Innovation Solution
A method and plug combination that securely attaches a verification element to the plug, which is released and removable only when the plug and mating plug are correctly locked together, allowing for verification of the connection state without the need for direct inspection of the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If connection position assurance devices are used to secure the lock between plug and mating plug, then the reliability of connection is improved, but the ability to check connection state after assembly is lost
Solution Approach 1:
A verification element is introduced as an intermediary component that mediates between the locking mechanism and the inspection process. This verification element can be removed only when the connection is properly established, serving as a tangible indicator that the locking mechanism has engaged correctly. The verification element translates the internal locking state into an externally observable condition without interfering with the locking function itself.
Solution Approach 2:
The verification element creates a copy or representation of the connection state. Instead of directly inspecting the complex locking mechanism, inspectors can verify the simpler state of the verification element (present or removed). This copying approach allows indirect verification of the connection state, making inspection feasible without disassembling or interfering with the secured locking mechanism.
2Stability of the object's composition
If the plug and mating plug are securely locked together, then the connection stability is improved, but the ability to remove verification element for inspection is restricted
Solution Approach 1:
The verification element is pre-configured to be removable only under specific conditions (when the connection is properly established). This preliminary design ensures that the verification element will naturally become removable once the locking mechanism engages, without requiring additional operations or compromising the secured connection. The removal capability is built into the design as a conditional feature rather than a post-connection modification.
3Manufacturing precision
If connection position assurance devices are implemented, then the manufacturing precision of connection is improved, but the device complexity increases
Solution Approach 1:
The connection system is segmented into distinct functional components: the locking mechanism for securing the connection, and the verification element for indicating connection status. This segmentation allows each component to be optimized independently - the locking mechanism focuses on secure engagement while the verification element focuses on providing inspectable feedback. The modular approach reduces overall complexity by separating concerns that would otherwise be intertwined in a monolithic design.
Data Source
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AI summary
The method according to the invention comprises the following steps: a) securely attaching the verification element (5) to the plug (4); b) connecting the plug (4) and mating plug (3); c) locking together the plug (4) and mating plug (3) whilst simultaneously releasing the attachment of the verification element (5); and d) removing the verification element (5) from the plug (4).