Self-Aligning Module Mount and Connector for Robotic Assembly
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional methods for installing electronic modules in electrified vehicles are complex due to numerous wire connections and require manual intervention, lacking efficient alignment and securing mechanisms, which can lead to damage from vibration and heat.
Innovation Solution
A self-aligning mechanical mount and electrical connection system with a mechanical mount assembly and electrical connection assembly, featuring mount and connector CPA features, robotic installation features, and heat transfer devices, allowing automated installation and secure connection of electronic modules.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manual installation methods are used for electronic modules, then installation can be completed with basic tools, but installation time is excessive and labor costs are high
Solution Approach 1:
The electronic module is designed with self-aligning features including alignment pins that automatically guide the module into the correct position on the base frame, and self-connecting electrical contacts that automatically engage with connector terminals. This eliminates the need for complex alignment tools and manual connection procedures, enabling rapid automated installation while maintaining simplicity in the installation system.
Solution Approach 2:
The electrical connectors and mounting features are pre-positioned and pre-configured on the electronic module housing before installation. The module includes pre-attached electrical contacts and alignment features that are ready for immediate engagement, eliminating the need for on-site wiring and alignment adjustments during the installation process.
2Reliability
If multiple wire cables are connected to electronic modules, then complete electrical connectivity is achieved, but installation complexity and time consumption increase significantly
Solution Approach 1:
Multiple individual wire connections are merged into a single integrated electrical connector assembly. The connector includes multiple contacts and terminals arranged in a compact configuration that establishes all necessary electrical connections simultaneously through a single engagement action, rather than requiring separate connections for each wire.
Solution Approach 2:
The electrical connection system is segmented into modular components including the electronic module with integrated contacts, the base frame with connector housing, and terminal elements. This modular segmentation allows for standardized interfaces and simplified assembly, where each segment is designed to engage with others in a predetermined sequence without complex wiring procedures.
3Stability of the object's composition
If electronic modules are securely mounted to resist vibration, then mechanical stability is improved, but heat dissipation capability may be compromised
Solution Approach 1:
The mounting system provides different local qualities at different contact points: rigid mounting feet and alignment pins provide mechanical stability and vibration resistance at the mounting interface, while dedicated heat sink elements and thermal pathways provide heat dissipation at the thermal interface. This localized differentiation allows simultaneous optimization of both vibration resistance and heat dissipation.
Solution Approach 2:
Thermal interface materials and heat transfer compounds are introduced as intermediaries between the electronic module housing and the base frame heat sink surfaces. These intermediary materials enhance thermal conductivity while maintaining mechanical contact stability, facilitating effective heat transfer without compromising the rigid mechanical connection needed for vibration resistance.
4Extent of automation
If automated robotic installation is implemented, then installation speed and cost efficiency increase, but precise alignment and securing mechanisms are required
Solution Approach 1:
The electronic module incorporates self-aligning features such as protrusion-alignment pin pairs and self-centering connector interfaces that automatically guide the module into precise position during robotic installation. These features eliminate the need for complex robotic positioning systems and sensors, allowing standard automated handlers to achieve precise alignment through the module's inherent mechanical guidance features.
Solution Approach 2:
The mounting system includes compliance elements such as spring-loaded mounting feet and flexible connector terminals that accommodate minor positioning variations and tolerances. These beforehand cushioning features ensure reliable mechanical and electrical connections even when robotic placement precision varies within normal tolerances, preventing installation failures without requiring ultra-precise robotic positioning.
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
Facilitates rapid, automated installation of electronic modules with reduced complexity, ensuring secure alignment, vibration resistance, and effective heat dissipation, thereby enhancing installation efficiency and reliability.
Implementation Method 1
a spring member arranged between the reception housing and the holding housing. When said insertion housing is inserted into said reception housing, said reception housing is pushed toward the insertion housing and first and second connecting terminals are coupled with each other by a restoring force of the spring means
Implementation Method 2
features for robotic assembly... heat transfer devices... effective heat dissipation
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3A~3B
AI summary
A self-aligning mechanical mount and electrical connection system for an electronic module (300) comprises a mechanical mount assembly (100) configured to be integrated into or attached to a base frame and defining a mount connection position assurance (CPA) feature (112) for self-aligning and securing of the electronic module (300) therein, and an electrical connection assembly (204) configured to be integrated into or attached to the mechanical mount assembly (100) and comprising a modular electrical connector (212) being electrically connected to an electrical backbone wire cable (208) and defining a connector CPA feature (120) for self-aligning the modular electrical connector (212) with a corresponding electrical connector (312) integrated into or attached to the electronic module (300) when the electronic module (300) is secured in the mechanical mount assembly (100).