Vehicle Wire Connector Assembly Verification Circuit
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Solution Overview
Problem
The existing connection methods for wiring harnesses in vehicles are complex and time-consuming, often leading to assembly errors that can cause malfunctions in electrical devices due to the lack of a reliable method to verify proper assembly of male and female connectors.
Innovation Solution
A wire connector system that includes a male connector, a female connector, and a circuit portion with transformation portions and test terminals, allowing a continuity tester to detect correct assembly by flowing current through the circuit when the male terminals are maximally inserted into the female terminals, preventing assembly errors and malfunctions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If direct connection of wiring harness to electric device is used, then connection simplicity is improved, but assembly time and complexity increase significantly
Solution Approach 1:
The wiring harness system is segmented into multiple connectors (male connector with male terminals and female connector with female terminals) that can be independently assembled and connected. This segmentation allows for modular assembly where each connector can be prepared separately and then quickly mated, reducing overall assembly time while maintaining simplicity of connection.
2Productivity
If traditional connector assembly is used, then connection speed is improved, but assembly accuracy and reliability deteriorate due to lack of verification
Solution Approach 1:
The patent incorporates a feedback mechanism through the circuit portion and continuity tester that provides immediate verification of proper connector assembly. When the male and female connectors are correctly assembled, the circuit portion completes an electrical circuit that can be tested with a continuity tester, providing feedback confirmation that the assembly is correct. This ensures assembly accuracy without significantly impacting connection speed.
3Device complexity
If connector assembly without verification is used, then manufacturing complexity is reduced, but product reliability deteriorates due to undetected assembly errors
Solution Approach 1:
The patent incorporates verification elements (circuit portion, test terminals, and continuity tester capability) into the connector design itself, performing the verification action as part of the assembly process. The circuit portion is pre-installed within the connector housing, and test terminals are pre-positioned to enable continuity testing. This preliminary preparation of verification infrastructure allows for reliable product assembly without adding significant manufacturing complexity, as the verification capability is built-in rather than added as a separate post-assembly step.
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
Enables reliable detection of proper assembly of connectors, preventing electrical device malfunctions and simplifying the connection process by ensuring accurate and complete assembly of wiring harnesses in vehicles.
Implementation Method 1
a circuit portion through which a current supplied by a continuity tester flows
Data Source
AI summary
A wire connector for a vehicle may include: a male connector having male terminals; a female connector having female terminals into which the male terminals of the male connector are inserted; and a circuit portion through which a current supplied by a continuity tester flows. The continuity tester can detect whether the male connector and the female connector are assembled without error.