Connector mating assurance system and method

A connector mating assurance system includes a microphone configured to be located in a vicinity of a mating zone for electrical connectors. The microphone is configured to detect an audible sound when the electrical connectors are mated. An output unit is connected to the microphone and receives audio signals from the microphone. The output unit processes the audio signals for mating assurance. The output unit may provide feedback to an assembler based on the audio signals. The output unit may determine if the electrical connectors are properly mated based on the audio signals. The microphone may be held by the assembler proximate to the assembler's hand when assembling the electrical connectors.

BACKGROUND OF THE INVENTION

The subject matter herein relates generally to connector mating assurance systems and methods.

Insuring that mating pairs of electrical connectors are mated properly is important in electrical systems, particularly in electrical systems that exhibit vibration during operation, such as in automotive applications. For example, an electrical connector can be partially mated during a car assembly process, such as in a car assembly factory, and can pass conventional electrical assurance tests, such as tests that pass electrical signals through the electrical connectors to determine electrical connection of the connectors. However, once in operation, the car vibration can cause the electrical connectors to come loose and cause failure.

Conventional assembly methods for electrical connectors provide a mating mechanism, such as a latch, that produces a click when the latch latches in place. However, in an assembly situation, a worker may not properly hear the click due to background factory noises, or could confuse the click with other sounds that closely resemble a connector click. Some known systems use a double casing of the connector, where a second case only fits if the electrical connectors were properly mated. However, such systems have increased cost associated with the second case and increased labor time to assemble.

A need remains for a connector mating assurance system and method to detect proper mating of electrical connectors.

BRIEF DESCRIPTION OF THE INVENTION

In one embodiment, a connector mating assurance system is provided including a microphone configured to be located in a vicinity of a mating zone for electrical connectors. The microphone is configured to detect an audible sound when the electrical connectors are mated. An output unit is connected to the microphone and receives audio signals from the microphone. The output unit processes the audio signals for mating assurance. The output unit may provide feedback to an assembler based on the audio signals. Optionally, the output unit may determine if the electrical connectors are properly mated based on the audio signals. The microphone may be held by the assembler proximate to the assembler's hand when assembling the electrical connectors.

Optionally, the output unit may filter background noise to enhance the audio signals. The connector mating assurance system may include a second microphone to detect the background noise. The output unit may compare audio signals from the microphones to isolate the audible sounds associated with mating of the electrical connector from the background noise.

Optionally, the microphone detects the audible sound that occurs when a latch of one electrical connector latches to the corresponding electrical connector. The output unit may provide visual feedback to the assembler at a display screen based on the audio signals. The output unit may provide audio feedback to the assembler based on the audio signals.

Optionally, the output unit may compare the audio signal to one or more templates to determine the type of electrical connectors mated. The output unit may differentiate different types of electrical connectors based on the audio signals from the microphone. The output unit may provide different feedback based on the different types of electrical connectors mated. The output unit may be calibrated by determining audio signatures for each of the different types of electrical connectors. The output unit may process the audio signals by comparing the audio signals to the audio signatures to determine which electrical connectors were mated based on the audio signals received at the output unit.

In another embodiment, a connector mating assurance system is provided including a microphone worn by an assembler and configured to be located in a vicinity of a mating zone for electrical connectors. The microphone detects an audible sound when the electrical connectors are mated. A speaker is connected to the microphone and receives audio signals from the microphone. The speaker outputs sound to the assembler based on the audio signals.

In a further embodiment, a method of detecting electrical connector mating is provided that includes positioning a microphone in a vicinity of a mating zone for the electrical connectors, detecting an audible sound with the microphone when the electrical connectors are mated, transmitting audio signals based on the audible sounds detected by the microphone to an output unit, processing the audio signals at the output unit, and providing feedback to an assembler based on the audio signals.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1illustrates a connector mating assurance system100formed in accordance with an exemplary embodiment. The connector mating assurance system100provides feedback to an assembler to confirm that a pair of electrical connectors102,104is properly mated. In an exemplary embodiment, the connector mating assurance system100detects an audible sound when the electrical connectors102,104are mated. The connector mating assurance system100may use real time signal processing for mating assurance. The connector mating assurance system100provides feedback to the assembler that the electrical connectors102,104are properly mated. The audible verification aspect of the connector mating assurance system100may be used in conjunction with an electronic verification system or other quality control systems that tests the electrical connection between the electrical connectors102,104as a secondary verification system.

The connector mating assurance system100includes a microphone110that is located in a vicinity of a mating zone112for the electrical connectors102,104. The microphone110is connected to an output unit114and the output unit114receives audio signals from the microphone110. The microphone may be connected to the output unit114by a wired or a wireless connection. The output unit114may be a computer that processes the audio signals and provides feedback to the assembler based on the audio signals. The output unit114determines if the electrical connectors102,104are properly mated based on the audio signals as a form of audible verification of proper mating. The output unit114may filter background noise to enhance the audible sound for the assembler. For example, the connector mating assurance system100may include a second microphone110that listens for background noise and the output unit114may compare the audio signals from the microphones110to isolate the audible sounds associated with mating the electrical connectors102,104from the background noise. The output unit114may have other means of filtering the background noise detected by one or both microphones110.

In an exemplary embodiment, the microphone110may be held by the assembler proximate to the assembler's hand. For example, the microphone110may be strapped to the assemblers hand or may be integrated into a glove worn by the assembler. Alternatively, the microphone110may be positioned within the mating zone112in the vicinity where the assembler is mating the electrical connectors102,104. The microphone110may be embedded into or otherwise coupled to the electrical connectors102and/or104.

In an exemplary embodiment, the connector mating assurance system100may be adapted for use in an area where visibility of and accessibility to the mating zone112is limited. For example, the electrical connectors102,104maybe part of wire harnesses that are assembled and mated during assembly of a car in an automotive plant. The electrical connectors102,104may be mated in an area under the hood, behind the engine, behind the dashboard, under a seat, or in other difficult to see areas, making use of the audible clicking sound when the electrical connectors102,104are mated. The connector mating assurance system100enhances the audible sound providing various types of feedback to the assembler to ensure that the electrical connectors102,104are properly mated. Additionally, the mating of the electrical connectors102,104may occur in a noisy environment, such as in an assembly plant, manufacturing plant or elsewhere where the audible click made when the latch of the electrical connectors102,104latches may be unheard by the assembler.

The electrical connectors102,104may be any type of electrical connectors. In an exemplary embodiment, the connector mating assurance system100may be used during assembly of automotive electrical connectors. The electrical connectors102,104may be AMP® sealed or unsealed connectors, such as those commercially available from Tyco Electronics, Harrisburg Pa.FIGS. 2 and 3illustrate exemplary embodiments of different types of electrical connectors102,104. For example,FIG. 2illustrates an eight position header and an eight position receptacle having eight contacts and associated wires extending therefrom. The electrical connectors102,104illustrated inFIG. 3are twelve position header and receptacle connectors having twelve contacts and associated wires. Other types of electrical connectors102,104may be provided in alternative embodiments, such as two position connectors, four position connectors, six position connectors, fourteen position connectors, and the like. Other types of electrical connectors102,104other than rectangular connectors, such as circular connectors, may be provided in other alternative embodiments. The electrical connectors102and/or104may be board mounted connectors rather than being cable or wire connectors, such as a header connector that is integrated or coupled to equipment or components within the vehicle.

The connector mating assurance system100may be used for connector identification purposes, such as to identify latching of the eight position connectors as compared to the twelve position connectors (or other types of connectors). The header electrical connectors102include a deflectable latch106and the receptacle electrical connectors104include a catch108for the latch106. Optionally, the latch106of the twelve position header connector (FIG. 3) may be different than the latch106of the eight position header electrical connector102(FIG. 2). For example, the latches106may have different lengths, may be made of different materials, may have different shapes, and the like. The catches108may have different sizes, shapes, number of teeth, and the like. The different latches106and/or catches108have different audio signatures when latching to the corresponding catches108. For example, when the latch106engages the catch108an audible click may be made, such as when the latch106snaps down into position behind the catch108(or multiple clicks may be heard when multiple teeth are provided). The latch106and/or catch may be designed to have prominent audio signatures. Providing different latches106and/or catches108provides different audio signatures when the electrical connectors102,104are mated. The connector mating assurance system100may be configured to differentiate between the different audio signatures of the different types of electrical connectors102,104to identify the particular electrical connectors102,104that are mated.

Returning toFIG. 1, the microphone110detects the latch click(s) that occurs when the latch106is latched, signifying that the electrical connectors102,104are properly mated. The audio signal, including the audio signal corresponding to the latch click, is transmitted to the output unit114. The output unit114processes the audio signal and provides feedback to the assembler.

In an exemplary embodiment, the output unit114provides audible feedback to the assembler based on the audio signals. For example, a speaker116may be coupled to the output unit114and output from the output unit114may cause the speaker116to provide audible feedback. The speaker116may enhance (e.g., make louder) the click detected by the microphone110to make it easier or possible for the assembler to hear.

In an exemplary embodiment, the output unit114provides visual feedback to the assembler at a display screen118coupled to the output unit114. The display screen118may be a stationary monitor, such as a monitor setting on a desk, integrated into a computer or other system, or mounted to a wall, or may be a portable monitor, such as a monitor configured to be worn by or carried by the assembler. The display screen118may display visual confirmation that proper mating has occurred based on the audio signals processed by the output unit114, such as by displaying a particular color, displaying a particular icon, displaying words and/or symbols, and the like. The output unit114may determine the type of the electrical connectors102,104mated (e.g., eight position versus twelve position versus another type) and may display information relating to the particular type of electrical connectors102,104that have been mated. For example, during a particular assembly, the assembler may need to mate a four position connector, an eight position connector and a twelve position connector. After the assembler performs the mating, the assembler may refer to the display screen118to verify that all three connectors where mated. The display screen118may indicate that only two of the connectors were actually mated, causing the assembler to return to the vehicle and figure out which connector was not properly mated. Alternatively, the output unit114may identify which of the connectors were mated based on the audio signals and indicate on the display screen118which of the three connectors were properly mated and/or which of the three connectors were not properly mated.

In an exemplary embodiment, the output unit114may include or be coupled to a template module120that includes different templates of audio signatures (examples shown inFIG. 4) of different types of electrical connectors102,104(e.g., 2 position, 4 position, 6 position, 8 position, 12 position, etc.). The output unit114may compare the received audio signal from the microphone110to the various templates to determine which type of electrical connectors102,104was mated. For example, the template module120may have different time domain characteristics and/or frequency domain characteristics for the different types of electrical connectors102,104. The output unit114may correlate the audio signals against time domain templates and/or frequency domain templates to identify the particular type of electrical connectors102,104that are mated.

In an exemplary embodiment, the output unit114may include or be coupled to a calibration module122that is used to calibrate the output unit114and/or the template module120. For example, in a calibration mode, the electrical connectors102,104may be mated, preferably numerous times to increase the amount of data to calibrate the output unit114and/or template module120. Time domain characteristics, frequency domain characteristic and/or other characteristics of the audio signal associated with the mating (e.g. the click) detected by the microphone110may be recorded and a median or average time domain template, frequency domain template and/or other type of template may be determined for each type of electrical connector102,104(e.g., 2 position, 4 position, 6 position, 8 position, 12 position, etc.) that may be assembled and monitored by the connector mating assurance system100. The output unit114may be calibrated and programmed for use with any number of different types of electrical connectors102,104. Based on the unique signatures of the audible sound made when the particular types of electrical connectors102,104are mated, the output unit114is able to identify and determine exactly which type of electrical connectors102,104have been mated at any particular time. The output unit114provides feedback at the display screen118for the assembler to identify which types of electrical connectors102,104have been mated.

In an exemplary embodiment, the output unit114includes or is electrically connected to any electronic verification module124. The electronic verification module124sends signals through the electrical connectors102,104to verify that the electrical connectors102,104are electrically connected. The output unit114may verify which electrical connectors102,104have affirmatively passed the electronic verification module124and compare such list of electrical connectors102,104with the list of electrical connectors102,104that have affirmatively passed audible verification. Data from the output unit114and/or electronic verification module124may be sent to a master quality control database or system on the vehicle or at the assembly plant for review and/or verification of successful assembly of the electrical connectors102,104. Such information may be combined with information from other modules or systems.

As used herein, the terms “system,” “unit,” or “module” may include a hardware and/or software system that operates to perform one or more functions. For example, a module, unit, or system may include a computer processor, controller, or other logic-based device that performs operations based on instructions stored on a tangible and non-transitory computer readable storage medium, such as a computer memory. Alternatively, a module, unit, or system may include a hard-wired device that performs operations based on hard-wired logic of the device. Various modules or units shown in the attached figures may represent the hardware that operates based on software or hardwired instructions, the software that directs hardware to perform the operations, or a combination thereof.

“Systems,” “units,” or “modules” may include or represent hardware and associated instructions (e.g., software stored on a tangible and non-transitory computer readable storage medium, such as a computer hard drive, ROM, RAM, or the like) that perform one or more operations described herein. The hardware may include electronic circuits that include and/or are connected to one or more logic-based devices, such as microprocessors, processors, controllers, or the like. These devices may be off-the-shelf devices that are appropriately programmed or instructed to perform operations described herein from the instructions described above. Additionally or alternatively, one or more of these devices may be hard-wired with logic circuits to perform these operations.

It should be noted that the particular arrangement of components (e.g., the number, types, placement, or the like) of the illustrated embodiments may be modified in various alternate embodiments. In various embodiments, different numbers of a given module or unit may be employed, a different type or types of a given module or unit may be employed, a number of modules or units (or aspects thereof) may be combined, a given module or unit may be divided into plural modules (or sub-modules) or units (or sub-units), a given module or unit may be added, or a given module or unit may be omitted.

As used herein, the terms “software” and “firmware” are interchangeable, and include any computer program stored in memory for execution by a computer, including RAM memory, ROM memory, EPROM memory, EEPROM memory, and non-volatile RAM (NVRAM) memory. The above memory types are exemplary only, and are thus not limiting as to the types of memory usable for storage of a computer program. The individual components of the various embodiments may be virtualized and hosted by a cloud type computational environment, for example to allow for dynamic allocation of computational power, without requiring the user concerning the location, configuration, and/or specific hardware of the computer system.

FIG. 4illustrates exemplary templates of audio signatures corresponding to latching or mating (e.g., audible click) of different pairs of electrical connectors130,132,134,136,138. The pairs of electrical connectors130,132,134,136,138may be 2 position, 4 position, 6 position, 8 position, and 12 position electrical connectors, respectively; however templates for other types of connectors may be developed in other embodiments.FIG. 4illustrates time domain templates140,142,144,146,148for the five different pairs of electrical connectors130,132,134,136,138, respectively. Each of the time domain templates140,142,144,146,148have unique signatures.FIG. 4illustrates frequency domain templates150,152,154,156,158for the five different pairs of electrical connectors130,132,134,136,138, respectively. Each of the frequency domain templates150,152,154,156,158have unique signatures. The time domain templates140,142,144,146,148and/or frequency domain templates150,152,154,156,158may be compared to any audio signal received at the connector mating assurance system100(shown inFIG. 1) to detect the click sound and determine the type of connectors that are mated.

FIG. 5is a chart showing audible detection of latching or mating of connectors using the connector mating assurance system100(shown inFIG. 1). The recorded data160is processed by the output unit114over time. The output unit114detects events162, which may correspond to latching or mating of the connectors, and false events164, which may occur when the microphone110touches something, when the connectors touch some other component, such as if the connectors are touched together but not mated or if the connectors are dropped, when other noises occur in the assembly facility, such as using other tools or machines around the assembly factory, and the like. The false events164may be identified by the output unit114, such as by analyzing the audio signature of such false events164and comparing the audio signature to the templates. The events162are verified by comparing the audio signatures of the recorded data160to the templates. The time domain templates140,142,144,146,148and/or frequency domain templates150,152,154,156,158may be used to compare to the recorded data160. When an event162is detected, the output unit114may provide audible, visual or other feedback outputs166to the assembler to confirm that the connectors are properly mated.

FIG. 6illustrates a connector mating assurance system200formed in accordance with an exemplary embodiment. The connector mating assurance system200provides audible feedback to an assembler to confirm that a pair of electrical connectors202,204is properly mated. In an exemplary embodiment, the connector mating assurance system200detects an audible sound when the electrical connectors202,204are mated.

The connector mating assurance system200includes a microphone210that is located in a vicinity of a mating zone212for the electrical connectors202,204. In an exemplary embodiment, the microphone210may be held by the assembler proximate to the assembler's hand. For example, the microphone210may be strapped to the assemblers hand or may be integrated into a glove worn by the assembler. Alternatively, the microphone210may be positioned within the mating zone212in the vicinity where the assembler is mating the electrical connectors202,204. The microphone210may be embedded into or otherwise coupled to the electrical connectors202and/or204.

The microphone210is connected to an output unit214and the output unit214receives audio signals from the microphone210. The output unit214processes the audio signals and provides an audible output or feedback. In an exemplary embodiment, the output unit214is a speaker that provides an audible output. The output unit214may be an ear bud or headphone worn by the assembler to provide audible feedback to the assembler based on the audio signals. The connector mating assurance system200enhances the audible sound providing various types of feedback to the assembler to ensure that the electrical connectors202,204are properly mated. The output unit214may filter background noise to enhance the audible sound for the assembler.