Sense Pin Segmentation for Connector Detection Precision
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Solution Overview
Problem
Existing electrical connector assemblies face issues with sense pins providing an unreliable detection range, leading to false indications of electrical connection status, which can result in degraded performance or unnecessary resource diversion due to tolerance stack-ups and guide feature inconsistencies.
Innovation Solution
The electrical connector design incorporates a sense pin with an offset intermediate segment and a conductive tip segment, allowing for precise detection of de-mating beyond a predetermined distance by disengaging from physical contact at the intermediate segment and engaging at the tip segment, thereby reducing false indications and improving reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If guide features (chamfers, fillets, rounds) are included on sense pin tips to guide initial engagement, then ease of operation is improved, but measurement precision deteriorates due to tolerance stack-ups creating an unreliable detection range
Solution Approach 1:
The sense pin contact surface is divided into two distinct segments: a guide feature segment (chamfer, fillet, or round) for initial engagement guidance, and a separate detection segment (flat surface) for precise electrical connection detection. This segmentation allows each segment to perform its specific function without interference from tolerance stack-ups affecting the other.
Solution Approach 2:
The detection function is extracted from the guide features by providing a separate flat surface detection segment on the sense pin. This extracted detection segment eliminates the unreliable detection range caused by tolerance variations in the guide features, while the guide features continue to provide their guidance function.
2Reliability
If a broad detection range is used for the sense pin, then reliability of detection is improved, but measurement precision deteriorates due to false indications from tolerance stack-ups
Solution Approach 1:
Different segments of the sense pin are given different electrical properties: the guide feature segment may have varying conductivity due to tolerance stack-ups, but the detection segment is designed with specific local quality (flat surface geometry and material properties) that ensures reliable and precise detection regardless of variations in the guide features.
Data Source
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AI summary
An electrical connector (12) comprises a housing that holds electrical contacts (22) configured to mate with corresponding mating contacts (24) of a mating connector (14). The housing holds a sense pin (22a) that is configured to mate with a corresponding mating contact (24a) of the mating connector. The sense pin includes a tip segment (54) and a sensing segment (52) having respective different electrical characteristics. The tip segment extends from the sensing segment to a tip of the sense pin such that the sensing segment is offset from the tip along a length of the sense pin. The sensing segment is configured to indicate that the electrical contacts and the mating contacts are de-mated by more than a predetermined de-mating distance (PDD).