Connector Plugging Force Measurement With Load Cell Position Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing test apparatuses for verifying the plugging force during assembly of automotive components fail to accurately determine the magnitude and location of the force applied, leading to potential misalignment and connection failures due to inconsistent or off-center force application, especially under vibrations and accelerations.
Innovation Solution
A test apparatus comprising a load plate with orthogonally arranged axes and load cells that support the load plate, a processor to determine the magnitude and location of the plugging force relative to the axes, and a visual display unit to provide feedback on force application, ensuring correct alignment and force thresholds are met.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional insertion force testing methods are used with micro switches and springs, then the testing process is simple, but the measurement precision of force magnitude and location is insufficient
Solution Approach 1:
The testing apparatus is segmented into multiple load cells arranged at specific locations around the connector, with each load cell independently measuring force at its position. This segmentation enables precise determination of both force magnitude and application location by analyzing the distribution of forces across multiple measurement points.
Solution Approach 2:
A load plate is introduced as an intermediary element between the connector and the load cells. The load plate transfers the applied insertion force to multiple load cells, enabling accurate measurement of force magnitude and location. The load plate acts as a mediator that distributes the force to various sensing points for comprehensive measurement.
2Reliability
If manual push-click-tug testing is performed by operators, then the testing procedure is straightforward, but the reliability of connection verification is insufficient due to potential misalignment
Solution Approach 1:
The system provides automated feedback by processing load cell data to determine whether the insertion force meets required thresholds and whether the force was applied at the correct location. This feedback mechanism objectively verifies proper connector insertion, eliminating reliance on operator judgment and reducing the risk of misalignment while maintaining ease of operation through automated assessment.
3Manufacturing precision
If only force magnitude is tested without location verification, then the testing process is simple, but the connector may be misaligned or not fully seated
Solution Approach 1:
The measurement system transitions from one-dimensional force magnitude measurement to two-dimensional measurement by incorporating spatial location information. Load cells are positioned at multiple locations around the connector, and the system determines not only the magnitude of the applied force but also its precise location, adding a spatial dimension to the measurement capability.
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 apparatus accurately verifies the plugging force and its location, preventing misalignment and ensuring secure connections by providing real-time feedback on force magnitude and application, thereby enhancing the reliability of electrical connections in automotive components.
Implementation Method 1
A plurality of load cells support the load plate and are arranged at spaced locations about the load plate such that a plugging force applied to the first electrical component retained on the load plate... is transferred to the plurality of load cells
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A test apparatus for verifying plugging force an electrical component having sockets for receiving one or more corresponding plugs in a push fit arrangement. The test apparatus comprises a load plate with a support surface and orthogonally arranged first and a second axes. A holder retains the first electrical component on the load plate. A plurality of load cells support the load plate at spaced locations about the load plate. A plugging force applied to the first electrical component via the second electrical component is transferred to the plurality of load cells. A processor is provided for receiving load cell data from the load cells corresponding to the force applied to each load cell respectively. The processor determines the magnitude of the plugging force and the location at which the plugging force is applied to the first electrical comment relative to the first and second axes of the load plate based on the load cell data and the location of the load cells relative to the load plate.