ERROR PROOFING SYSTEM FOR ASSEMBLED SQUIB DEVICES

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.

TECHNICAL FIELD

The present disclosure generally relates to error proofing devices and, more specifically, to error proofing devices that detect a proper assembly of sub components.

BACKGROUND

Many vehicles today include air bag assemblies. The assembly includes an inflatable canister located in the steering column, the passenger-side dashboard, the side door panel, or seat. When a particular rate of deceleration is detected, the canister is inflated by an explosive device, known as a squib, which contains an explosive material. The explosive material is electronically actuated when a signal is transmitted thereto over a transmission medium (e.g., wires). The wires are attached to the squib via a squib connector which plugs into the squib socket. During assembly, an assembler installs the squib connector into the squib socket of the canister. It is common for an assembler to incorrectly install the squib connector into the squib socket of the canister or forget altogether to install the squib connector into the squib socket of the canister.

SUMMARY

In one aspect, an error proofing system is provided. The error proofing system includes an electronic control unit and an electrical device. The electrical device includes a body having a wireless transmitter electrically coupled to the electronic control unit and a head portion. The head portion has 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.

These and additional objects and advantages provided by the embodiments described herein will be more fully understood in view of the following detailed description, in conjunction with the drawings.

DETAILED DESCRIPTION

Vehicles according to the present disclosure include an airbag assembly. For the airbag assembly to inflate, a squib connector is used to fire a squib positioned within an inflatable canister to inflate the canister when a particular rate of deceleration is detected. During installation in a manufacturing facility, there is a possibility for an operator to incorrectly install the squib connector into the inflatable canister. As such, embodiments disclosed herein are directed to an error proofing system to confirm that the squib connector is seated within the canister. The error proofing system includes an electronic control unit and an electrical device. The electrical device has a body with a wireless transmitter electrically coupled to the electronic control unit and a head portion releasably coupled to the body. The head portion has three micro-switches arranged in a series configuration and electrically coupled to the wireless transmitter. The head is shaped and sized to receive a portion of the squib connector to make electrical contact between the squib connector and at least one of the three micro-switches and to make contact with an uppermost portion of the canister to make electrical contact between the canister and a different two micro-switches of the three micro-switches when installed onto the properly assembled squib device.

When the assembled squib device is not installed properly, at least one of the three micro-switches will not make contact with either or both of the squib connector and the canister. As such an electrical signal generated by a power source positioned within the head portion will not be transmitted beyond the at least one of the three micro-switches that is not making contact with either or both of the squib connector and the canister. When the assembled squib device is installed properly, the electrical signal is transmitted through each of the three micro-switches and is wirelessly transmitted from the wireless transmitter to the electronic control unit. As such, the electrical signal received by the electrical control unit is indicative of a properly assembled squib device.

As used herein, the term “electrically coupled” means that coupled components are capable of exchanging data signals and/or electric signals (e.g., current, voltage, and/or the like) with one another such as, for example, electrical signals via conductive medium, electromagnetic signals via air, optical signals via optical waveguides, electrical energy via conductive medium or a non-conductive medium, data signals wirelessly and/or via conductive medium or a non-conductive medium and the like.

Further, as used herein, the term “longitudinal direction” refers to the forward-rearward direction of the electrical device (i.e., in the +/−X-direction depicted in the coordinate axes ofFIGS.1A-1B and3). The term “lateral direction” refers to the cross-electrical device direction (i.e., in the +/−Y-direction depicted in the coordinate axes ofFIGS.1A-1B and3), and is transverse to the longitudinal direction. The term “vertical direction” or “below” or “above” refer to the upward-downward direction of the electrical device (i.e., in the +/−vehicle Z-direction depicted in the coordinate axes ofFIGS.1A-1B and3).

Referring now toFIGS.1A-1B and2-3, an error proofing system10(e.g. a pokayoke system) is schematically depicted. The error proofing system10as described herein determines whether an assembled squib device1(FIG.3) is properly assembled. The assembled squib device1includes a connector2that is seated within a canister4. As such, as discussed in greater detail herein, the error proofing system10detects when the connector2is not properly seated within the canister4.

The error proofing system10, as depicted inFIG.1A, includes an electrical device12and an electronic control unit14electrically coupled to the electrical device12. The electrical device12includes a body16and a head portion18. It should be appreciated that the electrical device12ofFIG.1Aand the electrical device12ofFIG.1Bare similar with exception of the body16and the head portion18are each differently shaped. As such, like features will use the same reference numerals and the various differing aspects will use prime symbols to designate between the different body16and/or head portion18when needed.

The body16extends between a distal end20aand an opposite receiving end20b, as best illustrated inFIG.1B. The body16further includes an outer surface22aand an opposite inner surface22bextending between the distal end20aand an opposite receiving end20b. The receiving end20bmay include a cavity24. In some embodiments, the cavity24extends from the receiving end20bterminating at the distal end20a. In other embodiments, the cavity24extends from the receiving end20band terminates somewhere between the receiving end20band the distal end20a.

In some embodiments, the receiving end20band/or the cavity24may be circular in shape, as best depicted inFIG.1B. In other embodiments, the receiving end20band/or the cavity24may be any shape, such as square, rectangular, hexagonal, and/or the like. In some embodiments, the body16may be a cylindrical in shape, as best illustrated inFIG.1B. In other embodiments, the body16may be triangular, as best illustrated inFIG.1A. It should be understood that these shapes of the body16are non-limiting and the shape of the body16may be square, hexagonal, octagonal, irregularly shaped, and/or the like. In embodiments, portions of the body16may be used as a handle26by an operator to hold and maneuver the electrical device12to perform the functionality of the electrical device12, as described in greater detail herein.

A mounting member28extends from the outer surface22aof the body16. In some embodiments, the mounting member28is a plate that includes an exterior surface30. In other embodiments, the mounting member28may be unsitrut, round stock, and/or the like. In some embodiments the mounting member28is integrally formed with the body16. That is, the mounting member28and the body16are a monolithic structure. In other embodiments, the mounting member28is a separate structure that is coupled to the body16via at least one fastener, such as a nut and bolt, screw, rivet, adhesive, epoxy, and/or the like. The mounting member28defines an aperture32that provides access to the cavity24. The aperture32provides access for electrical components, such as electrical wires, to travel between the cavity24and the mounting member28.

The body16may be formed using injection molding techniques and/or additively manufacturing. In some embodiments, the body16may be formed from a nylon material. In other embodiments, the body16may be formed from a plastic material such as a polymer, a polyetheretherketone (PEEK), and the like. In other embodiments, the body16may be formed from materials suitable for injection molding or additive manufacturing such as Acrylonitrile Butadiene Styrene (ABS), Polyethylene (PE), Polyamide (Nylon), High Impact Polystyrene (HIPS), Polypropylene (PP), and the like. In other embodiments, the body16may be a steel, a composite metal, ceramic, concrete, resin, or any other suitable material that may be in solid, liquid, powder, sheet material, wire, or any other suitable form.

As used herein, the term “additively manufactured” refer generally to manufacturing processes wherein successive layers of material(s) are provided on each other to “build-up,” layer-by-layer, a three-dimensional component. The successive layers generally fuse together to form a monolithic component which may have a variety of integral sub-components. Although additive manufacturing technology is described herein as enabling fabrication of complex objects by building objects point-by-point, layer-by-layer, typically in a vertical direction, other methods of fabrication are possible and within the scope of the present subject matter. For example, although the discussion herein refers to the addition of material to form successive layers, one skilled in the art will appreciate that the methods and structures disclosed herein may be practiced with any additive manufacturing technique or manufacturing technology. For example, embodiments of the present invention may use layer-additive processes, layer-subtractive processes, or hybrid processes.

A wireless transmitter34may be coupled to the exterior surface30of the mounting member28via at least one fastener35, such as a nut and bolt, screw, rivet, and/or the like. The wireless transmitter34is electrically coupled to the electronic control unit14to wirelessly transmit signals from the electrical device12to the electronic control unit14. In some embodiments, the wireless transmitter34may include a built in LED display36to communicate a go/no-go condition to the operator. Further, the wireless transmitter34may include a power source38that independently provides power to the transmitter. In some embodiment the power source38may be a battery. In other embodiments, the power source38may be a corded application such as 110V, 220V, and/or the like. Further, as discussed in greater detail herein, the wireless transmitter34may be electrically coupled to components of the head portion18.

The head portion18includes an outer surface42aand spaced apart opposite inner surface42b. A continuous wall44separates or spaces the outer surface42afrom the inner surface42bsuch that a cavity is formed between the outer surface42athe inner surface42band between portions of the continuous wall44. The head portion18further includes an engagement portion40aand an opposite coupling portion40b. In some embodiments, the coupling portion40bincludes the inner surface42band may include a portion of the continuous wall44, as discussed in greater detail herein. For example, in the embodiment ofFIG.1A, the coupling portion40bextends from the inner surface42band is positioned below the continuous wall44of the head portion18in the vertical direction (i.e., in the +/−Z direction of the coordinate axes ofFIG.1A). In the embodiment ofFIG.1B, the coupling portion40bof the head portion18′ or18″ includes the inner surface42band a portion of the continuous wall44. As such, at least a portion of the coupling portion40bis received within the cavity24.

The coupling portion40bmay shaped to compliment the shape of the receiving end20bsuch that the coupling portion40bis received by the receiving end20b. For example, in bothFIGS.1A-1B, the coupling portion40bis illustrated as cylindrical. This is non-limiting, and the coupling portion40bmay be any shape, such as square, triangular, octagonal, hexagonal, and/or the like. Such an arrangement permits for interchangeability of the head portion18,18′,18″, and others. That is, the head portion18is releasably coupled to the body16, as best illustrated inFIG.1Aand the head portion18′,18″ are each releasably coupled to the body16′. Further, this is non-limiting as the head portion18may be coupled to the body16′ and/or the head portion18′,18″ may be coupled to the body16. In some embodiments, at least one fastener76, such as a nut and bolt, screw, rivet, and/or the like, couples the head portion18to the body16and/or couples the head portion18′,18″ to the body16′. As such, a plurality of differently sized and shaped head portions may be utilized to correspond or compliment the size and shape of the connector2and canister4of the assembled squib device1.

Referring now back toFIG.1A, the continuous wall44is generally square in shape. In some embodiments, a pair of arcuate portions60extend between the inner surface42band the engagement portion40ain the vertical direction (i.e., in the +/−Z direction). The engagement portion40aof the head portion18includes a pair of spaced apart recessed channels46. The pair of recessed channels46are each positioned below a portion of the outer surface42ain the vertical direction (i.e., in the +/−Z direction) and extend partially into the continuous wall44in the lateral direction (i.e., in the +/−Y direction). In some embodiments, each of the pair of recessed channels46are rectangular shaped and include a floor48and a multi-step portion50extending from a floor surface52of the floor48in the vertical direction (i.e., in the +/−Z direction). In other embodiments, each of the pair of recessed channels46may be other shapes such as elliptical, circular, square, and/or the like. The floor48of each of the pair of recessed channels46opens into the continuous wall44below the outer surface42ain the vertical direction (i.e., in the +/−Z direction).

Each of the pair of recessed channels46include an aperture54positioned within the multi-step portion50. In some embodiments, the aperture54positioned within the multi-step portion50of each of the pair of recessed channels46is centered within the multi-step portion50. In other embodiments, the aperture54positioned within the multi-step portion50of each of the pair of recessed channels46is offset from the center point, or not centered, within the multi-step portion50. Each aperture54is configured to receive a micro-switch56of the head portion18, as discussed in greater detail herein. A third aperture58is positioned within the engagement portion40aextending through the outer surface42aof the head portion18. As such, the third aperture58is positioned above the aperture54positioned within the multi-step portion50of each of the pair of recessed channels46in the vertical direction (i.e., in the +/−Z direction). The third aperture58is configured to receive a micro-switch56of the head portion18, as discussed in greater detail herein.

Referring now back toFIG.1B, the continuous wall44of the head portion18′,18″ is generally cylindrical in shape. The engagement portion40aof the head portion18′,18″ includes a single recessed channel46. The recessed channel46is positioned below a portion of the outer surface42ain the vertical direction (i.e., in the +/−Z direction) and extends partially into the continuous wall44in the longitudinal direction (i.e., in the +/−X direction of the coordinate axes ofFIG.1B). The recessed channel46may be rectangular shaped and includes the floor48and the multi-step portion50extending from the floor surface52of the floor48in the vertical direction (i.e., in the +/−Z direction). In other embodiments, the recessed channel46may be other shapes such as elliptical, circular, square, and/or the like. The floor48opens into the continuous wall44below the outer surface42ain the vertical direction (i.e., in the +/−Z direction).

The recessed channel46of the head portion18′ includes the aperture54positioned within the multi-step portion50. In some embodiments, the aperture54positioned within the multi-step portion50is centered within the multi-step portion50. In other embodiments, the aperture54positioned within the multi-step portion50is offset from the center point, or not centered, within the multi-step portion50. The aperture54is configured to receive the micro-switch56of the head portion18, as discussed in greater detail herein. A pair of elongated slots62are positioned within the engagement portion40aextending through the outer surface42aof the head portion18′. As such, the pair of elongated slots62are positioned above the aperture54positioned within the multi-step portion50of the recessed channel46in the vertical direction (i.e., in the +/−Z direction). The pair of elongated slots62extend in the longitudinal direction (i.e., in the +/−X direction). Each of the pair of elongated slots62are configured to receive the micro-switch56of the head portion18′, as discussed in greater detail herein.

The engagement portion40aof the head portion18″ includes the single recessed channel46. The recessed channel46is positioned below a portion of the outer surface42ain the vertical direction (i.e., in the +/−Z direction) and extends partially into the continuous wall44in the lateral direction (i.e., in the +/−Y direction of the coordinate axes ofFIG.1B). The recessed channel46may be rectangular shaped and include the floor48. In other embodiments, the recessed channel46may be other shapes such as elliptical, circular, square, and/or the like. The floor48opens into the continuous wall44below the outer surface42ain the vertical direction (i.e., in the +/−Z direction).

The recessed channel46includes an elongated slot66positioned to extend through the floor surface52. In some embodiments, the elongated slot66is centered within the recessed channel46in both the lateral (i.e., in the +/−Y direction) and the longitudinal direction (i.e., in the +/−X direction). In other embodiments, the elongated slot66is offset from the center point, or not centered, in either the lateral (i.e., in the +/−Y direction) and/or the longitudinal direction (i.e., in the +/−X direction). The elongated slot66extends in the longitudinal direction (i.e., in the +/−X direction). The elongated slot66is configured to receive the micro-switch56of the head portion18, as discussed in greater detail herein.

A pair of elongated slots68are positioned within the engagement portion40aextending through the outer surface42aof the head portion18″. As such, the pair of elongated slots68are positioned above the elongated slot66positioned within the recessed channel46in the vertical direction (i.e., in the +/−Z direction). Each of the pair of elongated slots68extend in the lateral direction (i.e., in the +/−Y direction). Further, each of the pair of elongated slots68are configured to receive the micro-switch56of the head portion18″, as discussed in greater detail herein.

The head portion18,18′,18″ may be formed using injection molding techniques and/or additively manufacturing. In some embodiments, the head portion18,18′,18″ may be formed from a nylon material. In other embodiments, the head portion18,18′,18″ may be formed from a plastic material such as a polymer, a polyetheretherketone (PEEK), and the like. In other embodiments, the body16may be formed from materials suitable for injection molding or additive manufacturing such as ABS, PE, Nylon, HIPS, PP, and the like. In other embodiments, the head portion18may be a steel, a composite metal, ceramic, concrete, resin, or any other suitable material that may be in solid, liquid, powder, sheet material, wire, or any other suitable form.

Now referring toFIG.2, a circuit70is schematically depicted. The circuit70includes the micro-switches56, a power supply72, and the wireless transmitter34arranged in a series configuration. The power supply72is positioned before the micro-switches56and the wireless transmitter34is positioned after the micro-switches56. It should be understood that each of the micro-switches56are formed with a conductive material such that when a structure makes contact with the respective micro-switch56, the micro-switch56moves within the head portion18(e.g., within each aperture54,58of the head portion18, or within each of the aperture54and the pair of elongated slots62of the head portion18′, or within the elongated slot66and the pair of elongated slots68of the head portion18″) to make contact with electrical components within the cavity of the head portion18, such as the circuit70, to electrically change from a normally open position, as illustrated inFIG.2, into a closed position. The closed position permits an electrical signal74to pass through the micro-switch56. In other embodiments, the movement from the normally open position into the closed position may occur when the micro-switches56make contact with an external conductive material, such as a conductive material that makes contact with the engagement portion40aof the head portion18.

As illustrated, there may be three micro-switches56, one for each aperture54,58of the head portion18, or one for the aperture54and one for each elongated slot of the pair of elongated slots62of the head portion18′, or one for each of the elongated slot66and the pair of elongated slots68of the head portion18″. As such, because of the series arrangement, the electrical signal74, generated by the power supply72, must pass through each of the three micro-switches56before the electrical signal74is received by the wireless transmitter34, which in turn transmits the electrical signal74to the electronic control unit14(FIG.1A). As such, for the electrical signal74to be transmitted from the power supply72to the wireless transmitter34, each of the three micro-switches56must be in the closed position. As the closed position for the micro-switch56may only occur when each of the three micro-switches56are in contact with a structure to move the respective micro-switch56into the closed position, the micro-switches56and the series arrangement form the error proofing or pokayoke, requiring all three micro-switches be in the closed position for the electrical signal74to pass through them.

Now referring toFIG.3, example assembled squib devices1with the connector2seated in various positions within the canister4are schematically depicted. Further, example head portions78,78′,78″,78′″ positioned onto the example assembled squib devices1to determine whether the assembled squib devices1is properly assembled are schematically depicted. It should be understood that the example head portions78,78′,78″,78′″ may be the head portion18, the head portion18′, the head portion18″, or another configuration of the head portion.

The head portion78is configured to be positioned onto the assembled squib device1. The recessed channel46of the engagement portion40areceives at least a portion of the connector2and the outer surface42amakes contact with an uppermost surface6of the canister4. As illustrated with respect to the head portion78, none of the micro-switches56have been moved from the normally open position into the closed position. That is, there is a gap between each respective micro-switches56and the connector2and the uppermost surface6of the canister4represented by arrows A1and A2, respectively.

That is, the recessed channel46receives a portion of the connector2extending beyond the uppermost surface6of the canister4in the vertical direction (i.e., in the +/−Z direction). As such, the micro-switch56extending within the aperture or elongated slot of the recessed channel46of the head portion78is not making contact with the connector2resulting in a gap or space, depicted by arrow A2. This results in the micro-switch56positioned in the recessed channel46remaining in the normally open position. Further, the micro-switches56extending from the outer surface42awithin the apertures or elongated slots of the head portion78are both not making contact with the uppermost surface6or surface of the canister4resulting in a gap or space, depicted by arrow A1. This results in the micro-switches56positioned to extend through the outer surface42aremaining in the normally open position. As such, because the micro-switches56of the head portion78would not be moved into the normally closed position, the electrical signal74(FIG.2) would not be transmitted to the wireless transmitter34(FIG.2) resulting in a fail or no-go condition for this particular assembled squib devices1not properly assembled.

The head portion78′ illustrates a condition where the micro-switch56extending within the aperture or elongated slot of the recessed channel46of the head portion78is making contact with the connector2and the micro-switches56extending from the outer surface42awithin the apertures or elongated slots of the head portion78are both making contact with the uppermost surface6of the canister4. As such, all three of the micro-switches56are in the normally closed position resulting in the electrical signal74(FIG.2) being transmitted to the wireless transmitter34(FIG.2) and, in turn, the wireless transmitter34(FIG.2) transmitting the electrical signal74to the electronic control unit14indicating a pass or go condition for this particular assembled squib devices1being properly assembled.

The head portion78″ illustrates a condition where the micro-switch56extending within the aperture or elongated slot of the recessed channel46of the head portion78is making contact with the connector2. As such, the micro-switch56positioned in the recessed channel46is now in the closed position. However, the micro-switches56extending from the outer surface42awithin the apertures or elongated slots of the head portion78are both not making contact with the uppermost surface6of the canister4resulting in a gap or space, depicted by arrow A1. As such, the connector2is not fully seated within the canister4resulting in the micro-switches56positioned to extend through the outer surface42aremaining in the normally open position. In this configuration, the electrical signal74(FIG.2) would not be transmitted to the wireless transmitter34(FIG.2) resulting in a fail or no-go condition for this particular assembled squib devices1not properly assembled.

The head portion78′″ illustrates a condition where the micro-switches56extending from the outer surface42awithin the apertures or elongated slots of the head portion78are both making contact with the uppermost surface6of the canister4but the micro-switch56extending within the aperture or elongated slot of the recessed channel46of the head portion78is not making contact with the connector2. As such, the micro-switch56positioned in the recessed channel46remains in the normally open position, as indicted by the arrow A2depicting the gap from the connector2and the micro-switch56. As such, in this condition, the connector2is not seated properly within the canister4resulting in the micro-switch56positioned within the recessed channel46to remain in the normally open position. In this configuration, the electrical signal74(FIG.2) would not be transmitted to the wireless transmitter34(FIG.2) resulting in a fail or no-go condition for this particular assembled squib devices1not properly assembled.

It should be appreciated that the failure of the wireless transmitter34(FIG.2) to transmit the electrical signal74(FIG.2) to the electronic control unit14(FIG.1A) may result in a line stop action. That is, the electronic control unit (FIG.1A) may be electrically coupled to other processors that control movement of an assembly line and the failure of the electrical signal74(FIG.2) transmitted to the electronic control unit14(FIG.1A) may result in the electronic control unit14(FIG.1A) communicating a line stop command to the other processors that control movement of the assembly line to stop the assembly line from movement until the electrical signal74(FIG.2) is received by the electronic control unit14(FIG.1A).

It should now be understood that the present disclosure is directed to an error proofing system to confirm that the squib connector is seated within the canister. The error proofing system uses a head portion that includes three micro-switches arranged in a series configuration to make electrical contact between the squib connector and to make contact with an uppermost portion of the canister such that the switches are moved from a normally open position into a closed positon, thereby allowing an electrical signal to pass through each of the switches to a transmitter that transmit a signal wirelessly as an indication that the squib connector is properly seated within the canister.