Vehicle Ultrasonic Sensor Connector Terminal Segmentation
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Solution Overview
Problem
Conventional ultrasonic sensors for vehicles have a bulky connector structure that increases production costs and installation complexity due to the need for multiple conductive terminals, making it difficult to integrate them into vehicle bumpers without disassembling the sensor into parts.
Innovation Solution
A compact ultrasonic sensor design featuring a connector with multiple terminal strips, including first and second sections that branch out to facilitate easier electrical connections, reducing the overall size and allowing for easier installation by minimizing the width and height of the connector, thus simplifying the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the connector is designed with multiple conductive terminals to avoid tying ground and communication cables, then the harness production cost is reduced, but the overall size of the sensor casing increases
Solution Approach 1:
The connector is segmented into a first terminal strip with a first section leading to the sensor device and a second section extending toward the opening, and a second terminal strip with a first section leading to the sensor device and at least two branched second sections extending toward the opening. This segmentation allows the terminal strips to be arranged compactly within the connector, reducing the overall connector size while maintaining multiple conductive terminals for separate ground and communication cables, thus resolving the contradiction between reducing harness production cost and minimizing sensor casing size.
2Reliability
If the connector size is increased to accommodate multiple conductive terminals, then the electrical connection reliability is improved, but the installation difficulty increases and disassembly is required
Solution Approach 1:
The terminal strips utilize three-dimensional spatial arrangement within the connector body, with sections extending in different directions toward the opening. The first terminal strip has its second section extending toward the opening, while the second terminal strip has branched second sections extending toward the opening. This dimensional arrangement allows multiple conductive terminals to be packed efficiently without increasing the connector's external dimensions, enabling reliable electrical connections while maintaining easy installation without disassembly.
3Productivity
If the connector is designed with a compact structure, then the installation time is reduced, but the number of conductive terminals is reduced requiring cable tying
Solution Approach 1:
Multiple terminal functions are merged into integrated terminal strip structures. The first terminal strip combines a first section leading to the sensor device with a second section extending toward the opening, creating a unified conductive path. The second terminal strip combines a first section with at least two branched second sections, integrating multiple electrical connections into a single component. This merging reduces the number of separate connectors needed, eliminates cable tying requirements, and maintains compact dimensions for quick installation.
Data Source
AI summary
A distance sensor for vehicles is provided which includes a sensor device and an electric connector for an electrical connection between the sensor device and a mating connector. The connector includes at least one first terminal pin and at least one second terminal pin. The first terminal pin has a first section leading to the sensor device and a second section extending toward an inlet opening of the connector. The second terminal pin has a first section leading to the sensor device and at least two branched second sections extending toward the inlet opening of the connector. Specifically, the second terminal pin is shaped to provide two-pin plugs, thereby permitting the size of the connector to be reduced, which facilitates ease of installation of the distance sensor to, for example, a bumper of the automotive vehicle.