VERIFICATION SYSTEM OR VERIFICATION METHOD FOR DETECTING A CONNECTOR POSITION ASSURANCE (CPA) DEVICE'S CLOSURE RELATIVE TO A HOUSING USING A MACHINE OR ELECTRIC/ELECTRONIC SCAN SYSTEM FOR READING OR DETECTING SURFACE SCAN OF SIZE OR SHAPE

Abstract

A verification system for detecting a connector position assurance (CPA) device's closure relative to a corresponding housing, The verification system includes a connector position assurance (CPA) device having a first visible or visual surface; a housing having a second visible or visual surface; and a scan system that scans the first visible or visual surface of said CPA device and said second visible or visual surface of the housing. The the scan system detects whether the CPA device is in full-lock position relative to the housing depending on whether the scan system detects whether the first and second visible or visual surfaces are separated from each other or joined together. Also, a verification method for detecting a CPA device's closure relative to the housing, which includes a step of detecting whether the CPA device is in a pre-lock position or in a full-lock position relative to the housing based on whether the scan system detects whether the first and second visible or visual surfaces are separated from each other or joined together. The scan system or scanning step also detects whether the CPA device is in a pre-lock position or in a full-lock position relative to the housing based on whether the scan system or scanning step detects that a predetermined percentage of a predetermined size or shape has been formed by at least one of a first medium on the CPA device and a second medium on the housing is within a scan window.

Claims

1. A verification system for detecting a connector position assurance (CPA) device's closure relative to a housing, comprising: a connector position assurance (CPA) device having a first visible or visual surface; a housing having a second visible or visual surface; and a scan system that scans said first visible or visual surface of said CPA device and said second visible or visual surface of said housing, wherein said scan system detects whether said CPA device is in full-lock position relative to said housing depending on whether said scan system detects whether said first and second visible or visual surfaces are separated from each other or joined together.

2. The verification system for detecting said CPA device's closure relative to said housing according to claim 1, wherein said scan system detects that said CPA device is in a pre-lock position relative to said housing upon detection that said first and second visible or visual surfaces are separated from each other.

3. The verification system for detecting said CPA device's closure relative to said housing according to claim 2, wherein said scan system detects that said CPA device is in a full-lock position relative to said housing upon detection that said first and second visible or visual surfaces are joined together.

4. The verification system for detecting said CPA device's closure relative to said housing according to claim 3, wherein said scan system detects said first visible or visual surface as a first medium, and wherein said scan system detects said second visible or visual surface as a second medium.

5. The verification system for detecting said CPA device's closure relative to said housing according to claim 1, wherein said scan system is a machine or an electric/electronic scan system.

6. The verification system for detecting said CPA device's closure relative to said housing according to claim 4, wherein said scan system directs a scan window onto at least one of said first medium and said second medium, wherein when said scan system detects that at least one of said first medium and said second medium is below a percentage threshold within said scan window, the scan system detects that said CPA device is in a pre-lock position relative to said housing.

7. The verification system for detecting said CPA device's closure relative to said housing according to claim 4, wherein said scan system directs a scan window onto at least one of said first medium and said second medium, wherein when said scan system detects that at least one of said first medium and said second medium is at or above a percentage threshold within said scan window, the scan system detects that said CPA device is in a full-lock position relative to said housing.

8. The verification system for detecting said CPA device's closure relative to said housing according to claim 4, wherein when said scan system detects that a percentage of at least one of said first medium and said second medium is zero within said scan window, the scan system detects that said CPA device is in a pre-lock position relative to said housing.

9. The verification system for detecting said CPA device's closure relative to said housing according to claim 6, wherein said first medium of said CPA device is one of a UV coating, reflective coating, pad printing, laser etching, and engraving.

10. The verification system for detecting said CPA device's closure relative to said housing according to claim 7, wherein said first medium of said CPA device is one of a UV coating, reflective coating, pad printing, laser etching, and engraving.

11. The verification system for detecting said CPA device's closure relative to said housing according to claim 9, wherein said second medium of said housing is one of a UV, reflective matter, and specific color.

12. The verification system for detecting said CPA device's closure relative to said housing according to claim10, wherein said second medium of said housing is one of a UV, reflective matter, and specific color.

13. The verification system for detecting said CPA device's closure relative to said housing according to claim 4, wherein said scan system directs a scan window onto at least one of said first medium and said second medium, wherein when said scan system detects that at least one of said first medium and said second medium is below a percentage threshold of a size or shape within said scan window, the scan system detects that said CPA device is in a pre-lock position relative to said housing.

14. The verification system for detecting said CPA device's closure relative to said housing according to claim 4, wherein said scan system directs a scan window onto at least one of said first medium and said second medium, wherein when said scan system detects that at least one of said first medium and said second medium is at or above a percentage threshold of a size or shape within said scan window, the scan system detects that said CPA device is in a full-lock position relative to said housing.

15. A verification method for detecting a connector position assurance (CPA) device's closure relative to a housing, comprising the steps of: providing a connector position assurance (CPA) device having a first visible or visual surface; providing a housing having a second visible or visual surface; and scanning by a scan system said first visible or visual surface of said CPA device and said second visible or visual surface of said housing, wherein said scanning step is comprised of a step of detecting whether said CPA device is in a pre-lock position or in a full-lock position relative to said housing based on whether said scan system detects whether said first and second visible or visual surfaces are separated from each other or joined together.

16. The verification method for detecting said connector position assurance (CPA) device's closure relative to said housing according to claim 15, wherein said scanning step is comprised of a step of detecting that said CPA device is in a pre-lock position relative to said housing upon detection that said first and second visible or visual surfaces are separated from each other.

17. The verification method for detecting said connector position assurance (CPA) device's closure relative to said housing according to claim 16, wherein said scanning step is comprised of a step of detecting that said CPA device is in a full-lock position relative to said housing upon detection that said first and second visible or visual surfaces are joined together.

18. The verification method for detecting said connector position assurance (CPA) device's closure relative to said housing according to claim 15, wherein said scanning step is comprised of a step of directing a scan window onto at least one of a first medium of said CPA device and a second medium of said housing, wherein when said scan system detects that at least one of said first medium and said second medium is below a percentage threshold within said scan window, said scan system detects that said CPA device is in a pre-lock position relative to said housing.

19. The verification method for detecting said connector position assurance (CPA) device's closure relative to said housing according to claim 15, wherein said scanning step is comprised of a step of directing a scan window onto at least one of a first medium of said CPA device and a second medium of said housing, wherein when said scan system detects that at least one of said first medium and said second medium is at or above a percentage threshold within said scan window, said scan system detects that said CPA device is in a full-lock position relative to said housing.

20. A verification method for detecting a connector position assurance (CPA) device's closure relative to a housing, comprising the steps of: providing a connector position assurance (CPA) device having a first visible or visual surface thereon, said first visible or visual surface having a first medium; providing a housing having a second visible or visual surface thereon, said second visible or visual surface having a second medium; and scanning said first medium of said CPA device and said second medium of said housing, wherein said scanning step is comprised of a step of directing a scan window onto at least one of said first medium and said second medium, and wherein said scanning step is further comprised of a step of detecting whether said CPA device is in a pre-lock position or in a full-lock position relative to said housing based on whether said scanning step detects that a predetermined percentage of a predetermined size or shape has been formed by at least one of said first medium and said second medium within said scan window.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] FIG. 1A is an elevational view of a conventional electrical connector assembly having a CPA device in a pre-lock position relative to a corresponding housing.

[0018] FIG. 1B is an elevational view of the conventional electrical connector having the CPA device pushed away from the housing resulting in the CPA device becoming fully locked to the corresponding housing.

[0019] FIG. 2A is an elevational view of a conventional electrical connector assembly having a CPA device in a pre-lock position relative to a corresponding housing.

[0020] FIG. 2B is an elevational view of the conventional electrical connector having the CPA device pushed away from the housing resulting in the CPA device becoming fully locked to the corresponding housing.

[0021] FIG. 3A is an elevational view of a conventional electrical connector assembly having a CPA device in a pre-lock position relative to a corresponding housing.

[0022] FIG. 3B is an elevational view of the conventional electrical connector having the CPA device pushed towards the housing resulting in the CPA device becoming fully locked to the corresponding housing.

[0023] FIG. 4A is an elevational view of a conventional electrical connector assembly having a CPA device in a pre-lock position relative to a corresponding housing.

[0024] FIG. 4B is an elevational view of the conventional electrical connector having the CPA device pushed towards the housing resulting in the CPA device becoming fully locked to the corresponding housing.

[0025] FIG. 5A is an elevational view of a conventional electrical connector assembly having a CPA device in a pre-lock position relative to a corresponding housing.

[0026] FIG. 5B is an elevational view of the conventional electrical connector having the CPA device pushed towards the housing resulting in the CPA device becoming fully locked to the corresponding housing.

[0027] FIG. 6A shows top elevational views of a housing and a CPA device of this invention separately showing the housing and the CPA device of this invention, while FIG. 6B further shows the housing and the CPA device of this invention as being operably coupled together.

[0028] FIGS. 7A and 7B each shows a side elevational view of the housing having on the upper surface thereof a retention portion for accommodating therein the CPA device and a machine or electric/electronic scan system above the upper surface of the housing for detecting the position or status of the CPA device relative to the housing, FIG. 7A showing the CPA device in a pre-lock position or status relative to the housing, and FIG. 7B showing the CPA device in a full-lock position or status relative to the housing.

[0029] FIGS. 8A and 8B each shows a window scan for use by the machine or electric/electronic scan system for detecting the size, shape, or percentage of Medium No. 1 of the CPA device within the window scan, FIG. 8A showing the Medium No. 1 of the CPA device not having been accommodated within the window scan thereby indicating that the CPA device is in a pre-lock position or status relative to the housing, and FIG. 8B showing the Medium No. 1 of the CPA device having been accommodated within the window scan thereby indicating that the CPA device in a full-lock position or status relative to the housing.

[0030] FIGS. 9A and 9B each shows a window scan for use by the machine or electric/electronic scan system for detecting the size, shape, or percentage of Medium No. 1 of the CPA device and/or Medium No. 2 of the housing within the window scan, FIG. 8A showing that insufficient size, shape, or percentage of the Medium No. I of the CPA device and/or the Medium No. 2 of the housing has occupied the space within the window scan thereby indicating that the CPA device is in a pre-lock position or status relative to the housing, and FIG. 8B showing that sufficient size, shape, or percentage of the Medium No. 1 of the CPA device and/or the Medium No. 2 of the housing has occupied the space within the window scan thereby indicating that the CPA device is in a full-lock position or status relative to the housing.

[0031] FIG. 10 is a flowchart of a verification method of this invention for detecting the CPA device's closure relative to the housing using a machine or electric/electronic scan system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0032] Illustrated in FIG. 6A is, generally, a connector position assurance (CPA) device 10 and a connector assembly housing 20, the CPA device 10 and the housing 20 being shown separately. The housing 20 has an upper surface 30, wherein the upper surface 30 includes a retention portion 25 for accommodating therein the CPA device 10. The CPA device 10 may be a known and a well-established component with a well-understood functionality within the industry of connector assemblies and the industries using such devices. Generally, the CPA device 10, when in a full-lock position relative to the housing 20, ensures that a male terminal and a female terminal (not shown) housed within the housing 20 are fully engaged. Shown on an upper surface 23 of the CPA device 10 is a first visible or visual surface 28 capable of being detected by a machine or electric/electronic scan system 40 (see FIG. 7A). Also shown in FIG. 6A is a second visible or visual surface 32 on the upper surface 30 of the housing 20 similarly capable of being detected by the machine or electric/electronic scan system 40 (see, again, FIG. 7A).

[0033] In FIG. 6B, the CPA device 10 is accommodated within the retention portion 25 located in the upper surface 30 of the housing 20. As shown in FIG. 6B, the CPA device 10 is in a pre-lock position and ready to be pushed or moved in the direction towards the housing 20 into a full-lock position. The movement of the first visible or visual surface 28 of the CPA device 10 towards the second visible or visual surface 32 of the housing 20 is monitored or scanned by the machine or electric/electronic scan system 40, as more fully discussed below.

[0034] The machine or electric/electronic scan system 40 scans or detects the movement of the first visible or visual surface 28 on the upper surface 23 of the CPA device 10 relative to the second visible or visual surface 32 on the upper surface 30 of the housing 20. The first visible or visual surface 28 of the CPA device 10 may be referred to as a “Medium No. 1,” while the second visible or visual 32 of the housing 20 may be referred to as a “Medium No. 2.” As illustrated in FIG. 7A, the machine or electric/electronic scan system 40 detects that the first visible or visual surface 28 of the CPA device 10 is separated from the second visible or visual surface 32 of the housing 20, as illustrated and discussed earlier with respect to FIG. 6B. The detected separation between the first visible or visual surface 28 of the CPA device 10 and the second visible or visual surface 32 of the housing 20 is an indication that the CPA device 10 is not fully engaged or absorbed within the housing 20; i.e., the CPA device 10 is in a partial lock position or status relative to the housing 20. Although the machine or electric/electronic scan system 40 may have an alternative location relative to the upper surface 30 of the housing 20, the machine or electric/electronic scan system 40 may be located such that its scan transmitting signals 45 and scan receiving signals 50 are directed in a direction that is substantially perpendicular to the first visible or visual surface 28 (Medium No. 1) on an upper surface 23 of the CPA device 10 and the second visible or visual surface 32 (Medium No. 2) on the upper surface 30 of the housing 20, or at an angle based on its “angle of attack” in calculating the locations of the first visible or visual surface 28 of the CPA device 10 and/or the second visible or visual surface 32 of the housing 20 that is being scanned. The varied angle may come into play in tight locations where the scan system 40 may have to scan at a specific angle (e.g., 35°-40°) because the scan system 40 may not have an easy access to the first visible or visual surface 28 (Medium No. 1) on an upper surface 23 of the CPA device 10 and/or the second visible or visual surface 32 (Medium No. 2) on the upper surface 30 of the housing 20.

[0035] In FIG. 7B, the CPA device 10 has been moved or pushed towards the housing 20; and consequently, the first visible or visual surface 28 (Medium No. 1) of the CPA device 10 has joined or abutted against the second visible or visual surface 32 (Medium No. 2) of the housing 20. The joining or abutting of the first visible or visual surface 28 of the CPA device 10 with the second visible or visual surface 32 of the housing 20 is detected by the machine or electric/electronic scan system 40, which indicates that CPA device 10 is fully engaged with the housing 20 or is in full-lock position or status relative to the housing 20.

[0036] Alternatively, in this invention, a predetermined surface of known geometric shape or size can be partially or fully formed on the first visible or visual surface 28 (Medium No. 1) of the CPA device 10, and partially or fully formed on the second visible or visual surface 32 (Medium No. 2) of the housing 20. This structural arrangement or feature is such that when the CPA device 10 is fully engaged or in full-lock position or status relative to the housing 20, the combined first and second visible or visual surfaces 28, 32 (joined Medium No. 1 and Medium No. 2) forms a complete geometric surface with a predetermined shape and/or size that is recognizable or distinguishable to a human eye or the electronic eye of the manual or electric/electronic scan system 40. In addition, the human eye or the electronic eye of the manual or electric/electronic scan system 40 should be able to recognize or distinguish that the separation of the first and second visible or visual surfaces 28, 32 (separated Medium No. 1 and Medium No. 2) indicates that the CPA device 10 is not fully engaged with the housing 20 or is in a partial-lock position or status relative to the housing 20.

[0037] In this invention, each of the first visible or visual surface 28 (Medium No. 1) and the second visible or visual surface 32 (Medium No. 2) can partially form a size or shape that will add up to a fully formed size or shape when placed adjacent to each other, joined together, or abutting each other. For example, either the first visible or visual surface 28 (Medium No. 1) or the second visible or visual surface 32 (Medium No. 2) can make up substantially 25% of the overall recognized shape and/or size, and the other surface or medium will by default need to form the remaining substantially 75% of the overall recognized shape and/or size.

[0038] Also in this invention, the first visible or visual surface 28 (Medium No. 1) of the CPA device 10 and the second visible or visual surface 32 (Medium No. 2) of the housing 20 will be unable to exhibit a complete overall recognizable or detectable shape and/or size when the CPA device 10 is in a partial-lock position or status (also referred to as an “unlocked position” or “open position”) relative to the housing 20. The first visible or visual surface 28 (Medium No. 1) of the CPA device 10 and the second visible or visual surface 32 (Medium No. 2) of the housing 20 are required to form a complete overall recognizable or detectable shape and/or size when the CPA device 10 is in a full-lock position or status (also referred to as a “locked position” or “closed position”).

[0039] Furthermore, in this invention, the first visible or visual surface 28 (Medium No. 1) of the CPA device 10 and the second visible or visual surface 32 (Medium No. 2) of the housing 20 are distinguishable to a human eye or the machine or electric/electronic scan system 40 with respect to the remaining elements or portions of the CPA device 10 and the housing 20 by contrasting color, UV coating, reflective coating, pad printing, laser etching, engraving, or the like.

[0040] In, for example, FIGS. 8A and 8B, at least one of the first visible or visual surface 28 (Medium No. 1) of the CPA device 10 and the second visible or visual surface 32 (Medium No. 2) of the housing 20 may have a contrasting color relative to the color of the background (of, e.g., the color of the housing 20) from e.g., UV coating, reflective coating, pad printing, laser etching, engraving, or the like. Consequently, in FIG. 8A, a scan window 60 is established on the upper surface 30 of the housing 20 onto which the machine or electric/electronic scan system 40 directs its scanning function. In FIG. 8A, the machine or electric/electronic scan system 40 scans a space 65 within the scan window 60 and detects the percentage of a target image 70 (in this case, the Medium No. 1 located on an upper surface 23 of the CPA device 10). In FIG. 8A, it is detected that the percentage of the target image 70 within the scan window 60 is zero (or below a predetermined percentage threshold), which results in the machine or electric/electronic scan system's 40 detecting that the CPA device 10 is not fully engaged (or is in a pre-lock position or status) relative to the housing 20. That is, the machine or electric/electronic scan system 40 rejects a zero or a predetermined low percentage of space within the scan window 60 being filled with the target image (i.e., Medium No. 1), which may take the form of a UV coating, reflective matter, specific color, or the like.

[0041] On the other hand, in FIG. 8B, the CPA device 10 is pushed towards the housing 20 such that the Medium No. 1 on an upper surface 23 of the CPA device 10 approaches and joins or abuts the Medium No. 2 on the upper surface 30 of the housing 20. Upon the machine or electric/electronic scan system's 40 scanning or determining that the predetermined percentage threshold of the target image 70 (Medium No. 1) within the scan window 60 is met, the machine or electric/electronic scan system 40 determines that the CPA 10 is fully engaged to the housing 20 (or that the CPA device 10 is in a full-lock position or status relative to the housing 20).

[0042] That is, the machine or electric/electronic scan system 40 accepts a detected percentage higher than a predetermined threshold percentage of space within the scan window 60 of the target image 70 (Medium No. 1), which may take the form of a UV coating, reflective matter, specific color, or the like. Consequently, the machine or electric/electronic scan system 40 determines that the CPA 10 is fully engaged to the housing 20 (or is in a full-lock position or status relative to the housing 20).

[0043] In another embodiment of this invention, the machine or electric/electronic scan system 40 determines whether a predetermined percentage of space within a scan window 90 is filled by the Medium No. I on an upper surface 73 of the CPA device 70 and/or the Medium No. 2 on an upper surface 85 of the housing 80 for reading or detecting the locking status of the CPA device 70 relative to the housing 80. More particularly, as illustrated in FIGS. 9A and 9B, a retention portion 75 on the upper surface 85 of the housing 80 movably accommodates therein the CPA device 70. As shown in FIG. 9A, the CPA device 70, and therefore the Medium No. 1 thereabove, remains at a distance away from the housing 80, and therefore away from the Medium No. 2 thereabove. In this embodiment of this invention, the window scan 90 is focused on the Medium No. 1 of the CPA device 70, as shown in FIG. 9A, and the machine or electric/electronic scan system 40 detects that a predetermined percentage of space 100 within the window scan 90 is not sufficiently or satisfactorily filled by the Medium No. 1 of the CPA device 70 and/or the Medium No. 2 of the housing 80. Consequently, the machine or electric/electronic scan system 40 detects and records that the CPA device 70 is not fully engaged with the housing 80 or that the CPA device 70 is in a pre-lock position or status relative to the housing 80.

[0044] On the other hand, in FIG. 9B, when the CPA device 70 is moved or pushed towards the housing 80, and therefore, the Medium No. 1 of the CPA device 70 is moved or pushed towards the Medium NO. 2 of the housing 80, in this embodiment of this invention, the window scan 90 remains focused on the Medium No. 1 of the CPA device 70, as shown in FIG. 9B, and the machine or electric/electronic scan system consequently detects that a predetermined percentage of space 100 within the window scan 90 is sufficiently or satisfactorily filled by the Medium No. 1 of the CPA device 70 and/or the Medium No. 2 of the housing 80. Consequently, the machine or electric/electronic scan system 40 detects and records that the CPA device 70 is fully engaged with the housing 80 or that the CPA device 70 is in a full-lock position or status relative to the housing 80.

[0045] FIG. 10 is a flowchart of a verification method of this invention for detecting the CPA device's closure relative to the housing 20 using a machine or electric/electronic scan system 40, which uses the reference numbers for the initial embodiment described above for this invention, although this flowchart is similarly applicable in the other embodiments described above for this invention.

[0046] In the method of this invention, as illustrated in the flowchart of FIG. 10, in Step S1, the CPA device 10 is at a pre-lock position or status relative to the housing 20 (i.e., the CPA device 10 is not fully engaged with the housing 20). The electronic visual system 40 (also referred to above as the “machine or electric/electronic scan system 40”), in Step S2, detects that the Medium No. 1 on the CPA device 10 and the Medium No. 2 on the housing 20 are not yet joined or abutted together. In Step S3, the electronic visual system 40 outputs a visual signal that the CPA device 10 is in a pre-lock position or status relative to the housing 20. Thereafter, in Step S4, the CPA device 10 is moved or pushed towards or away from the housing 20 depending on which connector assembly system described above is applicable.

[0047] In Step S5, the electronic visual system 40 scans the Medium No. 1 on the CPA device 20 and the Medium No. 2 on the housing 20; and consequently, the electronic visual system 40 determines in Step S6 whether the Medium No. 1 on the CPA device 10 and the Medium 2 on the housing 20 are jointed together or abutting each other. A decision is then made that if Step S6 is in the affirmative, it is determined in Step S7 that the CPA device 10 is fully engaged or in full-position or status relative to the housing 20; and the electronic visual system 40 outputs a signal that the CPA device 10 is in full-lock position or status relative to the housing 20 in Step S8.

[0048] On the other hand, if a decision is made that Step S6 is in the negative, it is further determined in Step S9 whether the CPA device 10 and the housing 20 have a spring-loaded connection. If so, and if it is further detected in Step S10 that the Medium No. 1 on the CPA device 10 and the Medium No. 2 on the housing 20 are joined or abut together, then it is determined in Step S11 that the CPA device 10 is in full engagement with the housing 20 or that the CPA device 10 is in full-lock position or status relative to the housing 20. Thereafter, the electronic visual system 30 outputs a visual signal that the CPA device 10 is in full-lock position or status relative to the housing 20.

[0049] If, in Step S9, it is determined that the CPA device 10 and the housing 20 do not have a spring-loaded connection, the method returns to Step S4 whereby the CPA device 10 is moved or pushed towards or away from the housing 20 in Step S4; and the subsequent steps proceed until Step S7 or Step S11 (as discussed above) is reached wherein it is detected that the CPA device 10 is in full-lock position relative to the housing 20, and to Step S8 or Step S12 (as discussed above) wherein the electronic visual system 40 outputs a visual signal that the CPA device 10 is in full-lock position or status relative to the housing 20.

[0050] If, in Step S10, it is determined that the Medium No. 1 of the CPA device 10 and Medium No. 2 of the housing 20 are not yet fully pushed together or not yet abutting together, the method returns to Step S4 whereby the CPA device 10 is moved or pushed towards or away from the housing 20 in Step 4; and the subsequent steps proceed until Step S7 or Step S11 (as discussed above) is reached wherein it is detected that the CPA device 10 is in full-lock position relative to the housing 20, and to Step S8 or Step S12 (as discussed above) wherein the electronic visual system 40 outputs a visual signal that the CPA device 10 is in full-lock position or status relative to the housing 20.

[0051] Although the foregoing descriptions are directed to preferred embodiments in the manufacturing method for assembling at least the vertical disk ferrule of this invention, it is noted that other variations and modifications will be apparent to those skilled in the art, and may be made without departing from the spirit or scope of the invention.