Wiring Connector Position Assurance for Reliable Electrical Contact
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Solution Overview
Problem
Some wiring connectors may not be electrically connected despite mechanical connection, and they can be difficult to access once installed, requiring costly and time-consuming disassembly of components to rectify faulty connections.
Innovation Solution
The implementation of a connector position assurance device, such as a spring-loaded mechanism or slider terminal with a switch, that verifies and ensures electrical connection after mechanical connection by compressing against a spring or sliding along the connector to establish contact between wire terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wiring connectors are made secure and difficult to access once installed, then connection reliability is improved, but ease of repair deteriorates
Solution Approach 1:
The connector is divided into separate components including a housing, terminal, and positioning device that can be independently assembled and disconnected. This segmentation allows the connector to be securely installed while enabling individual components to be accessed or replaced without removing the entire assembly from the product.
Solution Approach 2:
A connector positioning device acts as an intermediary mechanism between the connector housing and the product structure. This positioning device provides secure retention during operation but can be independently accessed or removed to facilitate repair, serving as a mediator between the conflicting requirements of security and accessibility.
2Strength
If connector components are tightly integrated, then mechanical strength is improved, but ease of manufacture deteriorates
Solution Approach 1:
The connector assembly is segmented into distinct manufacturable components (housing, terminal, positioning device) that can be produced separately using optimized processes for each component, then assembled to achieve the required mechanical strength. This avoids the complexity of manufacturing a single integrated piece while maintaining structural integrity.
Solution Approach 2:
Multiple functional components are merged into a single connector assembly that achieves the required mechanical strength through their combined structure. The housing, terminal, and positioning device work together to provide the necessary strength while each component can be manufactured independently using simpler, more cost-effective processes.
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
Ensures reliable electrical connectivity and simplifies the process of accessing and repairing wiring connectors by providing a clear indication of connection status and facilitating easier disconnection in high voltage circuits.
Implementation Method 1
a spring-loaded mechanism or slider terminal with a switch, that verifies and ensures electrical connection after mechanical connection by compressing against a spring
Implementation Method 2
slider terminal with a switch, that verifies and ensures electrical connection after mechanical connection by compressing against a spring or sliding along the connector to establish contact between wire terminals
Data Source
AI summary
The disclosure generally pertains to systems and methods involving wiring connectors. In an example system, the system may include a first wire having a first connector portion, a second wire having a second connector portion, and a connector position assurance device configured to electrically connect the first wire to the second wire after the first connector portion is mechanically connected to the second connector portion. In an example method, a first connector portion of a first wire may be aligned against a second connector portion of a second wire. The first connector portion may then be moved towards the second connector portion. The first wire may then be electrically connected to the second wire via a connector position assurance device after the first connector portion is mechanically connected to the second connector portion.