RFID-Enabled Electrical Connector With CPA Shielding
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Solution Overview
Problem
The automotive industry faces significant warranty and quality issues due to mis-seated electrical connectors in motor vehicles, with existing solutions like Connector Position Assurance (CPA) features lacking reliable methods to verify proper installation, and high-power/high-voltage connectors lacking recordable proof of correct installation.
Innovation Solution
An RFID-enabled Electrical Connector is embedded with a CPA feature, where an RFID tag is shielded by conductive material until the connector is properly seated, allowing the RFID reader to confirm correct installation by exposing the tag when the connector is fully locked.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Connector Position Assurance (CPA) features are used to ensure proper connector seating, then connector reliability is improved, but there is no method to verify or record that the CPA feature is properly installed and deployed
Solution Approach 1:
The patent implements an RFID tag that provides feedback information about connector installation status. The RFID tag is positioned such that it can be read only when the connector is properly mated, providing real-time verification information to the assembly system and creating a record of proper installation.
Solution Approach 2:
The patent introduces an RFID tag as an intermediary element between the CPA feature and the verification system. This RFID tag serves as a mediator that carries installation verification information, enabling remote reading and recording of connector mating status without direct human inspection.
2Loss of information
If barcodes are used with CPA features to record installation, then some verification capability is provided, but the method requires open space around the CPA for reader access and additional employee intervention
Solution Approach 1:
The patent extracts the verification information capability from the external barcode system and embeds it directly into the connector assembly via an RFID tag. This eliminates the need for separate barcode readers and open space requirements, integrating the verification function within the connector itself.
Solution Approach 2:
The patent replaces the mechanical line-of-sight barcode reading system with an electromagnetic RFID reading system. This substitution allows reading the verification information through materials that block optical signals, eliminating the need for physical access to specific areas around the connector.
3Strength
If eyelets with torque and angle specifications are used for high-power connections, then connection strength is improved, but there is no method to prove proper installation
Solution Approach 1:
The patent incorporates the RFID tag into the connector assembly before installation, so that the verification capability is already in place. When the connector is properly installed with correct torque and angle, the RFID tag's position changes to allow reading, providing immediate proof of proper installation without requiring additional verification steps.
4Loss of information
If RFID tags are embedded in connector housings, then verification capability is provided, but the tags may be energized prematurely from the back side
Solution Approach 1:
The patent applies different material properties to different parts of the connector housing. The front portion where the RFID tag is located uses materials that allow RF signal transmission when properly mated, while the back portion uses RF-shielding materials to prevent premature energization of the RFID tag from the rear side.
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
This solution provides a quick, inexpensive, and error-proof method to verify proper installation of electrical connectors, reducing warranty costs and ensuring accurate recording of connector seating, which is not possible with current methods.
Implementation Method 1
RFID, or radio-frequency identification, uses electromagnetic fields generated by an RFID reader to automatically identify an object with an RFID tag. An RFID tag consists of a miniature radio transmitter and receiver on which is stored a unique string of digital data. The RFID reader transmits a digital pulse which causes the RFID tag to transmit its string of digital data in response.
Implementation Method 2
When the RFID tag is covered by the conductive material, it is shielded. When the RFID is shielded by the conductive material, the RFID reader cannot energize the RFID tag, because the RFID signal cannot reach the RFID antenna.
Data Source
AI summary
The present invention is an RFID-enabled electrical connector with connector position assurance (“CPA”) features. The RFID tag is only readable after the CPA features have been fully deployed. The electrical connector is comprised of at least two parts, a socket and a plug. In the illustrated embodiment, a connector housing is positioned between the socket and plug, with both the socket and plug connecting to the connector housing. Until the CPA feature has been fully deployed, the RFID tag is covered by an electrically conductive material, preferably an electrically conductive plastic. The RFID tag can only be properly read after the CPA feature has been fully deployed. To prevent signal leakage, the RFID tag can alternately be placed inside a five-sided box fabricated from electrically conductive material, preferably electrically conductive plastic.