Squib Connector Seating Verification With Wireless Micro-Switch Sensing
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Solution Overview
Problem
During the assembly of airbag systems in vehicles, there is a common issue of incorrectly installing or forgetting to install the squib connector into the inflatable canister, which can lead to improper inflation during deceleration events.
Innovation Solution
An error proofing system is introduced, comprising an electronic control unit and an electrical device with a wireless transmitter and micro-switches. The electrical device has a head portion with three micro-switches arranged in series, which make contact with the squib connector and the canister when properly aligned, ensuring an electrical signal is transmitted to confirm correct assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual assembly of squib connector into canister is used, then assembly process is simple and fast, but assembly errors occur frequently
Solution Approach 1:
The patent applies preliminary action by pre-configuring micro-switches within the inspection device that will detect assembly errors before the product leaves the assembly line. The micro-switches are positioned to make contact with specific features of the squib connector and canister, ensuring that any misassembly is detected before final assembly completion.
Solution Approach 2:
The inspection device with micro-switches acts as an intermediary between the assembler and the final assembled product. This intermediary device provides tactile feedback through the micro-switches to confirm proper assembly, serving as a mediator that verifies the connection between squib connector and canister without requiring complex electronic sensors or automated assembly mechanisms.
2Reliability
If inspection device with multiple micro-switches is used, then assembly verification is improved, but device complexity increases
Solution Approach 1:
The inspection device is segmented into multiple independent micro-switches, each responsible for detecting a specific aspect of assembly correctness. This segmentation allows the system to verify multiple assembly conditions simultaneously using simple, discrete components rather than a single complex sensor system.
Solution Approach 2:
The micro-switches are designed to be actuated by the assembly components themselves during the normal assembly process. The squib connector and canister features directly engage the micro-switches without requiring additional actuators or complex mechanisms, allowing the assembly process to self-verify through the micro-switch responses.
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
The system effectively verifies the proper seating of the squib connector within the canister by ensuring all micro-switches are in the closed position, preventing the transmission of an electrical signal unless the connector is correctly installed, thus preventing incorrect assembly and ensuring airbag functionality.
Implementation Method 1
micro-switches electrically coupled to the wireless transmitter such that an electrical signal is transmitted from a power supply to the wireless transmitter when each of the micro-switches are moved from an initial open position into a closed position. Each of the micro-switches are independently movable by contact with components of an assembled squib device when appropriately aligned.
Implementation Method 2
a body having a wireless transmitter electrically coupled to the electronic control unit
Data Source
AI summary
Embodiments herein are directed to an error proofing system that determines whether an assembled squib device is properly assembled is provided. The assembled squib device has a connector seated within a canister. The error proofing system includes an electronic control unit and an electrical device. The electrical device includes a body and a head portion. The body includes a wireless transmitter. The head portion includes three micro-switches electrically coupled to the wireless transmitter and is shaped and sized to receive a portion of the connector of the assembled squib device to make contact between the connector and at least one of the three micro-switches and to make contact with an uppermost surface of the canister such that a different two micro-switches of the three micro-switches make contact with the uppermost surface when the connector is properly installed within the canister to form the assembled squib device.