Self-Aligning Connector Carrier for Faster ECU Harness Mating
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Solution Overview
Problem
The installation of vehicle wiring harnesses is complex and requires significant effort due to the difficulty in reliably coupling connectors between cables and vehicle components, necessitating a more efficient and cost-effective electrical connection system.
Innovation Solution
A self-aligning modular electrical connector system with a common carrier and connector carriers that securely retain and position connectors to mate with an Electronic Control Unit (ECU), allowing for robotic installation and simplifying the connection process by using a main channel for cable bundles and side channels for connector carriers that move from a pre-staged to a staged position for locking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional wiring harness installation methods are used, then connectors can be coupled to establish electrical connections, but the installation process becomes complex and requires significant effort
Solution Approach 1:
The system divides the wiring harness into modular segments with pre-assembled connector carriers that can be independently handled and installed. Each connector carrier is a self-contained unit that can be manipulated as a single module, reducing the complexity of assembling multiple individual connectors.
Solution Approach 2:
The connector carrier acts as an intermediary device between the cable bundle and the ECU. It pre-organizes multiple connectors in a fixed spatial arrangement and provides a unified interface for coupling, simplifying the installation process by replacing multiple individual coupling operations with a single carrier-level operation.
2Productivity
If multiple connectors are coupled individually to establish electrical connections, then electrical connectivity is achieved, but significant time and effort are required
Solution Approach 1:
Multiple connectors are merged into a single integrated connector carrier assembly. The carrier holds multiple connectors in predetermined positions, allowing them to be coupled to the ECU simultaneously or in sequence as a unified unit, dramatically reducing the time required compared to coupling each connector individually.
Solution Approach 2:
The connectors are pre-positioned and pre-organized within the connector carrier during manufacturing or pre-assembly. This preliminary arrangement eliminates the need for time-consuming alignment and positioning operations during final installation, as the connectors are already in their correct spatial relationships.
3Reliability
If connectors are manually aligned and coupled, then reliable electrical connections are established, but the process requires significant skill and effort
Solution Approach 1:
The connector carrier incorporates self-aligning features such as guide rails, positioning pins, or tapered interfaces that automatically guide the connectors into correct alignment with the ECU during the coupling process. This self-alignment mechanism eliminates the need for manual alignment operations, reducing both the skill level required and the risk of misalignment while maintaining connection reliability.
4Manufacturing precision
If a rigid fixed-position connector system is used, then precise alignment is achieved, but the system lacks adaptability to different configurations
Solution Approach 1:
The connector carrier incorporates movable or adjustable components that allow the relative positions of connectors to be modified. The carrier can be configured in different arrangements or adjusted during installation to accommodate varying ECU positions or cable routing requirements, providing both precise alignment through controlled movement and adaptability to different configurations.
Data Source
AI summary
An electrical connection system is described which includes a common carrier. The common carrier includes a main channel configured to retain a cable bundle and a plurality of side channels that facilitate coupling of at least some cables of the cable bundle to an electronic control unit (ECU). The side channels are configured to retain a connector carrier configured to carry a pair of connectors slidable in each side channel between a pre-staged position in preparation for mating and a mated position which mates terminals carried by the pair of connectors and locks the pair of connectors to the ECU.