Protective Wiring Connector Assembly for Fast Multi-Connector Alignment
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Solution Overview
Problem
The increasing complexity of wiring installations in electric, hydrogen, and autonomous vehicles requires efficient methods to connect and protect numerous wires and connectors, as existing solutions result in excessive work time and risk of damage during assembly.
Innovation Solution
A wiring connector assembly that includes first and second protective covers to maintain accurate spacing between connectors, providing protection and facilitating easy connection by using locking protrusions and grooves, and partition walls for stable coupling, reducing the need for manual alignment and exposure to interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple wires and connectors are installed manually in the vehicle body, then the wiring connections can be established, but the work time becomes excessive and the risk of damage during assembly increases
Solution Approach 1:
The wiring system is divided into modular connector units, each containing pre-organized wires and connection components. These segmented modules can be independently handled and quickly installed, transforming a complex manual wiring task into a series of simple module installations.
Solution Approach 2:
Wires and connectors are pre-assembled into complete connector units before vehicle assembly. The connectors include pre-attached protective covers and locking mechanisms, allowing workers to simply install the complete unit rather than assembling multiple components during the wiring process.
2Productivity
If multiple wires and connectors are installed manually in the vehicle body, then the wiring connections can be established, but the risk of damage due to interference with other components increases
Solution Approach 1:
Protective covers are pre-installed on connectors before they enter the vehicle body. These covers act as a cushioning protection layer that prevents wires and connector terminals from being damaged by interference with other components during the assembly process.
Solution Approach 2:
By segmenting the wiring system into separate connector modules with protective covers, each module can be installed as a discrete unit, reducing the likelihood of wires getting caught or damaged during assembly operations.
3Manufacturing precision
If connectors are fastened together with accurate spacing, then the connection reliability improves, but the complexity of the fastening mechanism increases
Solution Approach 1:
The connector design incorporates self-aligning features where the housing structures and locking mechanisms automatically guide connectors into the correct spaced positions during installation. The system serves itself to maintain accurate spacing without requiring complex external fastening devices or precise manual positioning.
Solution Approach 2:
The fastening function and spacing maintenance function are merged into a single integrated connector housing design. The interlocking features of the connector housings simultaneously achieve both secure fastening and precise spacing, eliminating the need for separate positioning mechanisms.
4Object-affected harmful factors
If protective covers are used to cover and protect connectors and wires, then the protection against damage improves, but the device complexity increases
Solution Approach 1:
The protective cover is merged with the connector housing into a single integrated structure. The cover is not a separate accessory but an integral part of the connector design, providing protection while maintaining a compact and simple overall structure.
Solution Approach 2:
The connector housing serves multiple functions simultaneously: it provides structural support, maintains spacing, enables fastening through locking features, and protects internal wires and terminals. This multi-functionality eliminates the need for separate protective components, reducing overall complexity.
Data Source
AI summary
A wiring connector assembly includes a plurality of first connectors to which first wires are connected, a plurality of second connectors to which second wires are connected, the plurality of second connectors configured to be correspondingly connected to the plurality of first connectors, a first protective cover configured to fix the plurality of first connectors by a predetermined spacing and to cover and protect an outside of the plurality of first connectors and the first wires, and a second protective cover configured to fix the plurality of second connectors by a predetermined spacing and to cover and protect an outside of the plurality of second connectors and the second wires, wherein the first protective cover and the second protective cover are configured to be fastened to each other to allow the plurality of first and second connectors to be correspondingly connected to each other.