Self-Aligning Module Mount With Robotic Connector Alignment
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Solution Overview
Problem
The installation of electronic modules in automotive electrical systems is complex and time-consuming due to the need for numerous wire connections, and existing methods do not effectively secure modules against physical vibration or dissipate heat efficiently.
Innovation Solution
A self-aligning mechanical mount and electrical connection system that integrates a mechanical mount assembly with a mount connection position assurance feature and an electrical connection assembly, including a modular electrical connector connected to an electrical backbone wire cable, allowing for robotic assembly and heat transfer via heat pads, facilitating secure installation and efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manual installation methods are used for electronic modules, then complex wire connections can be made with human judgment, but installation time is excessive and labor costs are high
Solution Approach 1:
The electrical connection system is segmented into modular components: a backbone wire cable with integrated connectors that distributes power and data to multiple electronic modules independently. This segmentation allows robotic installation by breaking down the complex wiring task into standardized connector operations, dramatically improving installation speed while maintaining connection reliability
Solution Approach 2:
The backbone wire cable serves multiple functions simultaneously: it provides power distribution, data communication, and mechanical mounting support for multiple electronic modules. This multi-functionality reduces the number of separate components needed, simplifying the overall system while enabling faster automated installation through standardized interfaces
2Stability of the object's composition
If electronic modules are secured to minimize vibration damage, then mechanical stability is improved, but heat dissipation becomes challenging
Solution Approach 1:
The mounting system merges mechanical vibration isolation functions with thermal management functions into a single integrated structure. The mounting bracket or plate provides both mechanical securement against vibration and incorporates heat sink features or thermal pathways to conduct heat away from electronic modules, simultaneously addressing both stability and temperature control
Solution Approach 2:
A thermal interface material or heat transfer compound is introduced as an intermediary between the electronic module and the mounting structure. This intermediary facilitates efficient heat conduction from the module to the heat-dissipating mounting bracket while maintaining the mechanical connection needed for vibration resistance, resolving the conflict between securement and heat dissipation
3Reliability
If multiple wire cables are used to connect electronic modules to devices and other modules, then electrical connectivity is achieved, but installation complexity and time increase significantly
Solution Approach 1:
The backbone wire cable is pre-assembled with connectors attached at manufacturing, bringing the electrical connection interface to the cable itself. This preliminary action eliminates the need for field termination of individual wire cables, dramatically reducing installation time while ensuring reliable electrical connectivity through factory-tested connector assemblies
Solution Approach 2:
Multiple electrical connection functions are nested within the backbone wire cable structure: power conductors, data conductors, and grounding paths are all integrated into a single cable assembly with standardized connectors. This nesting consolidates what would otherwise require multiple separate cable installations into one operation, reducing installation time while maintaining comprehensive electrical connectivity
4Productivity
If robotic installation is implemented for electronic modules, then installation speed and cost efficiency improve, but precise alignment and securing of modules becomes difficult
Solution Approach 1:
The mounting system incorporates asymmetric or uniquely shaped positioning features such as shaped mounting tabs, keyed connectors, or non-circular alignment pins that provide foolproof orientation. These asymmetric features guide the robotic installer into the correct alignment position, eliminating the need for complex vision systems or precision positioning algorithms while ensuring accurate module placement and electrical connection
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 system enables faster, more efficient installation of electronic modules with reduced human intervention, improved vibration resistance, and effective heat management, enhancing the reliability and performance of automotive electrical systems.
Implementation Method 1
with features for robotic assembly... effective heat management... heat transfer via heat pads
Data Source
AI summary
A self-aligning mechanical mount and electrical connection system for an electronic module comprises a mechanical mount assembly configured to be integrated into or attached to a base frame and defining a mount connection position assurance (CPA) feature for self-aligning and securing of the electronic module therein, and an electrical connection assembly configured to be integrated into or attached to the mechanical mount assembly and comprising a modular electrical connector (i) being electrically connected to an electrical backbone wire cable and (ii) defining a connector CPA feature for self-aligning the modular electrical connector with a corresponding electrical connector integrated into or attached to the electronic module when the electronic module is secured in the mechanical mount assembly.