Integrated Sensor Connector Layout for Faster Harness Assembly
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Solution Overview
Problem
Conventional wire harnesses require multiple assembly steps, including connecting electric wires to temperature sensors and providing connector portions, which decreases assembly efficiency.
Innovation Solution
A component-attached connector that integrates a connection component, an electrical component, and a housing, with terminal portions extending away from the connection component, allowing direct connection to a counterpart connector, thereby omitting the need for separate wire connection and connector attachment steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If electric wires are connected to temperature sensors and connector portions are provided separately, then the wire harness can be assembled, but the assembly process becomes complex and time-consuming
Solution Approach 1:
The patent combines the temperature sensor, electric wires, and connector portion into an integrated assembly called a component-attached connector. The sensor housing holds both the temperature sensor and connector portion together, eliminating the need for separate assembly steps and reducing overall complexity.
Solution Approach 2:
The component-attached connector serves multiple functions simultaneously: it acts as a temperature sensor, provides electrical connections through the connector portion, and houses both components in a single integrated unit. This multi-functional design reduces the number of separate components needed.
2Ease of operation
If multiple separate components are used for temperature detection and electrical connection, then functional requirements are met, but the number of assembly steps increases
Solution Approach 1:
The temperature sensor and connector portion are pre-assembled together in the sensor housing before installation. This preliminary assembly means that when the component-attached connector is installed on the bus bar, both the sensing and electrical connection functions are already integrated, reducing on-site assembly steps and time.
3Device complexity
If the connector portion is integrated with the temperature sensor housing, then assembly is simplified, but the terminal portions must extend in specific directions
Solution Approach 1:
The terminal portions are designed to extend in directions away from the connection component, utilizing three-dimensional space efficiently. This dimensional arrangement allows the integrated structure to maintain both compactness and proper electrical connection orientation without increasing complexity.
Data Source
AI summary
A component-attached connector configured to be connected to a detection target to detect a physical quantity of the detection target, includes: a connection component configured to be connected to the detection target; an electrical component including an electrical component main body connected to the connection component to detect the physical quantity, and a pair of terminal portions connected to the electrical component main body and formed to extend in a direction away from the connection component; and a housing that holds the connection component and the electrical component, wherein the pair of terminal portions are configured to be connected to counterpart terminals of a counterpart connector.