Spring-Mounted Connector Holder for Wiring Harness Tolerance Fit
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Solution Overview
Problem
The assembly of electrical connectors in vehicle wiring harnesses is labor-intensive, prone to ergonomic issues, and often requires excessive tolerances, leading to inefficiencies and potential electrical failures, with existing solutions either increasing costs or compromising on design.
Innovation Solution
A connector holder with a main portion, attachment portions, and spring portions that allow elastic deformation, enabling movement in an oblique plane to accommodate tolerance variations and reduce assembly forces, thus facilitating easier and more precise connection of electrical connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual assembly of electrical connectors is used, then ease of operation is improved, but productivity deteriorates due to labor-intensive processes and increased assembly time
Solution Approach 1:
The connector holder incorporates spring portions that provide dynamic movement capability, allowing the holder to move relative to the base assembly part in a movement plane. This dynamic feature enables automated connectors to accommodate position tolerances and assemble successfully without requiring manual adjustment, thereby improving productivity while maintaining ease of operation through the self-adjusting mechanism.
2Manufacturing precision
If position tolerance for automated connector assembly is reduced to ~0.1 mm, then manufacturing precision is improved, but device complexity increases due to the need for precise mechanical part positioning
Solution Approach 1:
The spring portions enable the connector holder to dynamically adjust its position within a certain range, accommodating the ~0.1 mm tolerance requirement without demanding extremely precise mechanical positioning of the base assembly part. This dynamic compensation mechanism reduces the complexity of achieving and maintaining precise positional relationships between components.
Solution Approach 2:
The spring portions change the physical state of the connector holder from rigid to elastic, allowing it to deform and adapt to position variations. This parameter change enables the system to achieve high manufacturing precision (~0.1 mm tolerance) without requiring equally high precision in the mechanical part positioning, thereby reducing device complexity.
3Ease of operation
If wiring harness length is reduced for ergonomic improvement, then ease of operation is improved, but reliability deteriorates due to increased risk of connector breakage from assembly forces
Solution Approach 1:
The spring portions provide a dynamic cushioning effect that absorbs assembly forces through elastic deformation. This allows shorter wiring harnesses to be used for ergonomic improvement while the spring portions protect against breakage by accommodating assembly forces, thus maintaining reliability despite the reduced harness length.
Solution Approach 2:
The spring portions are pre-configured to provide cushioning against assembly forces before actual assembly occurs. This beforehand cushioning protects the connectors and wiring harness from breakage during the assembly process, enabling the use of shorter, more ergonomic harness lengths without compromising reliability.
4Strength
If connector holder is made rigid for structural stability, then strength is improved, but ease of operation deteriorates due to inability to accommodate position tolerances
Solution Approach 1:
The connector holder is segmented into rigid and flexible portions. The rigid portions (main body, attachment portions) provide structural stability and strength, while the spring portions provide flexibility to accommodate position tolerances. This segmentation allows the holder to simultaneously achieve strength and ease of operation through the combination of rigid and elastic features.
Solution Approach 2:
Different portions of the connector holder have different mechanical properties: the main body and attachment portions are rigid for structural stability, while the spring portions are elastic for tolerance accommodation. This local differentiation of quality allows the holder to provide both strength and operational ease in different locations as needed.
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 solution allows for greater tolerance ranges, reduces the risk of connector breakage, and improves ergonomics by enabling the use of shorter wiring harnesses and potentially enabling autodocking or automated assembly, while maintaining robustness to absorb high forces.
Implementation Method 1
at least two spring portions, each of the spring portions being connected to a respective one of the attachment portions and having a spring characteristic to allow movement of the main portion in a movement plane oblique to the assembly axis when the connector holder is attached to the base assembly part by means of the attachment portions
Data Source
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AI summary
The disclosure relates to a connector holder (10) for an electrical connection assembly (100) for a wiring harness (210) of a vehicle (200), the electrical connection assembly (100) and a vehicle (200) having the electrical connection assembly (100). The connector holder (10) comprising a main portion (11) for attaching a first electrical connector (40) of the electrical connection assembly (100) thereto or having the first electrical connector (40) attached thereto, a second electrical connector (50) being connectable to the first electrical connector (40) along an assembly axis (Z), the assembly axis (Z) extending along the attachment of the first electrical connector (40) to the main portion (11). The connector holder (10) comprising at least two attachment portions (14) for attaching the connector holder (10) to a base assembly part (30) of the electrical connection assembly (100), and at least two spring portions (15), each of the spring portions (15) being connected to a respective one of the attachment portions (14) and having a spring characteristic to allow movement of the main portion (11) in a movement plane (MP) oblique to the assembly axis (Z) when the connector holder (10) is attached to the base assembly part (30) by means of the attachment portions (14).