Vehicle Connection Interface Testing Arrangement
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Solution Overview
Problem
Conventional testing stations for vehicle components often fail to ensure accurate connection status verification, leading to potential assembly errors and increased maintenance costs due to incorrect connections in systems like fuel and cooling systems.
Innovation Solution
A testing arrangement that includes a tool with a sensor device and test adapter to measure the force progression during coupling of quick connector parts, utilizing an evaluation device to transmit control signals for assembly line actuation, thereby reducing incorrect assembly risks and eliminating the need for manual inspections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional testing stations use cameras to check connection status, then visual inspection capability is provided, but measurement precision and reliability of connection status verification are insufficient
Solution Approach 1:
The patent replaces optical inspection systems (cameras) with a mechanical sensing system. A sensor device integrated into the coupling tool directly measures physical parameters (force, position, progression) during the coupling process, providing quantitative data that is far more precise and reliable than visual inspection. This mechanical measurement approach captures the actual physical state of the connection interface.
Solution Approach 2:
The patent introduces a sensor device as an intermediary between the coupling tool and the control system. This sensor acts as a mediator that translates physical coupling parameters into measurable signals, enabling accurate verification of connection status. The sensor serves as the bridge that converts mechanical interaction into detectable data for evaluation.
2Productivity
If manual inspections are performed on connection interfaces, then flexibility in handling different connection types is maintained, but productivity and production time are reduced
Solution Approach 1:
The coupling tool is equipped with integrated sensor devices that automatically measure and evaluate connection parameters during the coupling process itself. The system performs self-verification without requiring separate manual inspection steps. The sensor device and evaluation device work together to automatically determine connection status, eliminating the need for human inspectors.
Solution Approach 2:
The patent performs connection verification during the coupling process itself, before the assembly leaves the station. By measuring force progression and position during coupling, the system verifies connection status in advance, allowing immediate detection and correction of defects without delaying production flow.
3Reliability
If no testing arrangement is used, then production speed is maintained, but the risk of incorrect assembly and subsequent defects increases
Solution Approach 1:
The patent combines the coupling function and testing function into a single integrated tool. The sensor device is built into the coupling tool, merging the mechanical coupling operation with the measurement operation. This integration ensures that every coupling action is automatically verified without requiring separate testing equipment or additional tooling.
Solution Approach 2:
The evaluation device receives real-time data from the sensor device during coupling and provides immediate feedback on connection status. The system compares measured parameters against predetermined criteria and can trigger alerts or stop the process if defects are detected. This closed-loop feedback ensures high reliability by immediately identifying incorrect assemblies.
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 effectively reduces the risk of defective vehicle gearboxes and system leaks, saving on maintenance and repair costs while optimizing production time and capacity by ensuring accurate coupling of vehicle components.
Implementation Method 1
at least one sensor device (7a, 7b) configured to acquire a force progression that acts in the connection interface (2) during and/or after the coupling
Data Source
AI summary
A testing device is disclosed for testing a connection interface coupled onto an assembly line between first and second vehicle components. The testing device includes a tool configured to couple the connection interface, at least one test adapter for testing the coupling of the connection interface, and a sensor device for acquiring a force progression which acts during and/or after the coupling in the connection interface. The testing device also includes an evaluation device to evaluate the force progression.