Power Connector Loose Connection Detection
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Solution Overview
Problem
Existing power connector systems fail to detect loose connections before they fully disconnect, leading to potential power loss in critical systems like vehicle steering systems, where vibrations can cause loose connections during operation.
Innovation Solution
Incorporating secondary housings with shorter male and female terminals that disconnect before the primary terminals, allowing for early detection of a loose connection through a detection circuit that measures voltage changes on a diagnostic sense line, providing a warning before the primary connection is lost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If existing detection tools and techniques are used to detect electrical disconnection, then the disconnection can be detected, but only after the electrical connection is already lost, not before
Solution Approach 1:
The secondary housing with shorter terminals is designed to disconnect before the primary housing, providing early warning of loose connections before they affect the main power connection. This preliminary detection action allows the system to alert operators before actual power loss occurs.
Solution Approach 2:
The secondary housing acts as an intermediary detection mechanism between the primary power connection and the monitoring system. It provides an intermediate stage that signals connection issues before they propagate to the main power transfer function.
2Measurement precision
If secondary housings with shorter terminals are added to enable early detection, then loose connections can be detected before disconnection, but the device complexity increases
Solution Approach 1:
The connector system is segmented into two functional parts: a primary housing for power transfer and a secondary housing for detection. This segmentation allows each part to be optimized for its specific function while working together as an integrated system.
Solution Approach 2:
The secondary housing is essentially a simplified copy of the primary housing structure, using the same basic connector design but with shorter terminals. This copying approach enables detection functionality without requiring entirely new complex mechanisms.
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
Enables early detection of loose power connections, preventing power loss by generating a warning to the driver before the primary terminals disconnect, thus ensuring continuous power supply to electrical components.
Implementation Method 1
A detection circuit is utilized to detect an open circuit condition between the secondary housings
Implementation Method 2
the detection circuit measures a 0V on a voltage diagnostic sense line when the secondary housings are fully connected and pull-up voltage of 12V is measured on the voltage sense line when the secondary housings are disconnected
Data Source
AI summary
An electrical connector assembly that includes a female and male connector assembly. The female assembly includes a primary female housing including two female terminals. A secondary female housing including two female terminals short circuited to one another. The secondary female housing affixed to a side of the primary female housing. A male connector assembly including a primary male housing including two male terminals. The two male terminals in contact with the two female terminals of the primary female housing when the primary male housing is seated in the primary female housing for providing electrical energy to the electrical component. A secondary male housing including two male terminals. The secondary male housing affixed to a side of the primary male housing, wherein at least one of the two male terminals have a shorter length than the at least two male terminals of the primary male housing.