TECHNICAL FIELD

[0001] The present subject matter generally relates to a connector unit and particularly but not exclusively relates to a connector unit for establishing electrical connection with an electronic device including a control device.

BACKGROUND OF THE INVENTION

[0002] Typically, most contemporary appliances or consumer goods including automobiles include a control device namely an electronic control unit. The control device is usually an embedded system that controls one or more corresponding electrical systems or subsystems in the corresponding appliances. Most appliances typically comprise a plurality of control devices and the complexity involved in establishing electrical connections for the plurality of control devices itself is very challenging. For example, it is especially challenging to ensure safety of the control device to which many power lines carrying high current are connected.

[0003] Hybrid and electric vehicles are typically provided with a plurality of control devices including at least one electronic control unit that controls one or more subsystems of the vehicle. For example, hybrid and electric vehicles typically includes a motor controller that converts DC power from the battery unit to AC power to drive a multi-phase motor unit/motor controller etc. Both DC power wires and AC power wires are required to be connected to the motor controller using couplers. Typically, the power wires are directly connected to the motor controller by using individual coupler for each power wire. However, in using individual couplers, there exists high possibility of wrong assembly with the power wires being routed to the wrong terminal during manufacturing as well as during service. Additionally, use of couplers to connect the power wires to the terminals on the controller makes them vulnerable to movement owing to vibrations, which can potentially result in power wires brushing one another, which may further result in power wires getting shorted and lead to fire hazard safety risk. Moreover, the assembly time required to route the power wires to the terminals on the motor controller is also high. Additionally, there lies a challenge of retaining the stable routing of the connections as well as the wiring during the assembly process. Typically, the control unit has a plurality of connections including incoming and outgoing signals or current. Assembly of multiple connector designs known in the art consume significant amount of time for an operator to individually fix each of the connections with added risk of mix-up which is highly undesirable especially for the power lines which are vulnerable for short circuit, major damage & fire accident. In a vehicle, especially a saddle type two wheeled vehicle, layout space is always a challenging limitation. Therefore, packaging one or more controllers to maintain a compact vehicle layout while still ensuring adequate utility space for the user becomes a contradictory requirement. Considering ease of manufacturing, one may prefer orienting the controller unit in an upward facing orientation which can enable operator to assemble the power lines as well other harness and connectors with less difficulty. However, such orientation of a controller eats away into valuable utility space making it a compromised solution. Disposing a controller unit in a vertical orientation though can minimise space requirement but can make the task of connecting the power lines / harness and couplers almost impossible. Thus, there exists a need for an improved solution for connecting harness and couplers to a controller overcoming all problems cited above as well as other problems of known art.

[0004] Therefore, there is a need for providing an alternate means for establishing electrical connections of an electronic device used in various appliances, while ensuring safety of the appliances, ease of assembly as well as enabling packaging in a compact layout. Moreover, there is also a need to ensure ease of access of the power wires to be connected to the electronic device, so that the overall time required for establishing electrical connections of the electronic device with the corresponding electrical components is reduced, and the overall productivity of manufacturing the various appliances is improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The detailed description described with reference to the accompanying figures. The same numbers have been used throughout the drawings to reference like features and components.

[0006] Fig.l is a top view of a connector unit depicting parts of the connector device in accordance with an embodiment of the present subject matter.

[0007] Fig.2 is a perspective exploded view of the connector unit installation of a connector guide cum cover member to the connector unit in accordance with an embodiment of the present subject matter.

[0008] Fig.3 is an exploded view depicting the assembly of power wires and the connector guide cum cover member to the connector unit during transit of the connector member in accordance with an embodiment of the present subject matter.

[0009] Fig.4 is a left perspective view of a two-wheeled vehicle including the connector unit in accordance with a first embodiment of the present subject matter.

[00010] Fig.5 is an exploded view depicting the configuration of the power wires and the connector guide cum cover member with respect to the connector unit, before assembly of the connector unit to a control device in accordance with an embodiment of the present subject matter.

DETAILED DESCRIPTION OF THE INVENTION

[00011] One or more control devices are typically provided in majority of the contemporary appliances/ products including automobiles for controlling one or more systems or sub systems of the corresponding appliance/product. Hybrid and electric vehicles are typically provided with a plurality of control devices including at least one electronic control unit that controls one or more subsystems of the vehicle. For example, the hybrid and electric vehicles typically include a motor controller that converts DC power from the battery unit to AC power to drive a multi-phase motor unit. The motor control unit receives a plurality of power lines including AC and DC power lines that get connected to corresponding terminals on the motor control unit via standard couplers. Most often, each AC and DC power line is connected via an individual coupler. Thus, a plurality of couplers are used to connect the plurality of power lines to the motor control unit. However, while use of couplers aids in coupling the power lines to the motor control unit, it does not aid in preventing movement of power lines due to vehicle vibration. Movement of power lines due to vehicle vibration, shock loads etc. results in friction between them, resulting in the power lines getting shorted. Additionally, movement of power lines also causes the couplers to get loosened, thereby resulting in arcing at the point of contact of the couplers with the power lines, putting the hybrid/electric vehicle at a safety risk. Moreover, with use of individual couplers, there exists a high possibility of wrong assembly with the power wires being routed to the wrong terminal, which gets further aggravated with more number of lines to be connected. High assembly time is also another disadvantage associated with the use of individual couplers for coupling the power lines to the motor control unit, as the workmen at the assembly line are required to individually couple each power line with a coupler for establishing electrical connection of the motor control unit with a battery unit and a motor unit. Accessing the corresponding terminals on the motor control unit for connection with the power lines becomes especially difficult when the motor control unit has been mounted vertically in the vehicle, with the corresponding terminals on the motor control unit pointing sidewards and away from the centre of the vehicle. Such configuration may be preferred to maintain a compact layout but makes the assembly extremely difficult & unviable Moreover, even once the power lines are coupled to the corresponding terminals on the motor control unit, the power lines would dangle vertically downwards from the motor control unit, subjecting the power lines to strain undesirably. Therefore, there is a need to provide an alternate configuration for establishing electrical connection of any control device with its corresponding power lines.

[00012] With the above and other objectives in view, the present subject matter provides a stand-alone connector unit for housing a plurality of power lines to be connected with a corresponding control device for establishing electrical connection of the control device with its corresponding circuit components. The connector unit comprises a connector base for holding two or more power lines, and two or more corresponding terminal slots for receiving corresponding terminal members of said two or more power lines, wherein each corresponding terminal slot receives a corresponding terminal member of each power line. As per an embodiment, the connector base is integrally extended to form the corresponding terminal slots. Particularly, the corresponding terminal slots are formed in a manner such that each terminal slot is at a predefined distance from the neighboring terminal slot, so that each power line of the two or more power lines is held at a predefined distance from the neighboring power line. Thus, it is ensured that all power lines to be connected to the control device are held away from one another. Further, in order to prevent movement of each of said two or more power lines, the connector unit comprises a plurality of holder arms, wherein a pair of holder arms each of the plurality of holder arms extends on either side of each terminal slot of the two or more corresponding terminal slots. When each power line of the two or more power lines connected to a terminal member each is located in each terminal slot of the two or more corresponding terminal slots, a pair of crimped terminal arms formed in each terminal member attached to each power line is pressed against each pair of holder arms. Thus, each power line is secured in each corresponding terminal slot of the two or more corresponding terminal slots of the connector unit and is prevented from moving even due to vehicle vibration. The connector unit holding the two or more power lines is directly assembled over the control device, without having to individually couple each power line to the corresponding terminals of the control device. Therefore, assembly time required for connecting power lines to the control device is significantly reduced. As per an aspect of the present invention, the connector unit is used to pre-configure all the connecting power lines in their desired position as a sub-assembly before it is being assembled on the vehicle or the product. This greatly enhances the degree of freedom with which the operator can accomplish the assembly of the power lines in a pseudo sub-station in any desired & comfortable orientation irrespective of the final orientation of the assembly on the vehicle.

[00013] As per an aspect of the present subject matter, each power line of the two or more power lines emerging from a wiring harness and to be housed in the connector unit is configured to have a length different than the others, so that each power line together with its terminal member can only be located in its corresponding terminal slot and in no other terminal slot. Thus, it is ensured that no power line can be wrongly assembled on the connector unit.

[00014] As per another aspect of the present subject matter, the connector unit is provided with a connector guide cum cover member, wherein on one surface of the connector guide cum cover member, a plurality of ribs is formed. In order to ensure that the two or more power lines are held in their respective terminal slots, before the final assembly of the connector unit is assembled over the control device, the connector unit as a stand-alone assembly is pre-locked with the connector guide cum cover member on its bottom side, with the two or more corresponding terminal slots holding the corresponding terminal members of the two or more power lines getting located over the plurality of ribs formed in connector guide cum cover member. Provision of connector guide cum cover member in the bottom side of the connector unit ensures that the two or more power lines to be connected to the control device remain in their positions even during transit of the connector unit in the/ to the assembly line from a separate sub-assembly station. Further, when the connector unit holding the two or more power lines is about to be assembled over the control device, the connector guide cum cover member is unlocked from the bottom side of the connector unit. In addition, once the connector unit is assembled, the connector guide cum cover member is inverted or flipped with its second surface facing a top surface of the connector unit and is locked against the top surface of the connector unit. Thus the guide performs the dual function of being a guide during sub-assembly & a cover after being assembled on the vehicle. The connector guide when functioning as a cover member on the top surface of the connector unit helps prevent entry of dust and water into the corresponding terminal members of the two or more power lines. Thus, the connector guide cum cover member serves as a guide when the same is locked against the bottom side of the connector unit and as a cover when the same is locked against the top surface of the connector unit.

[00015] Thus, the design and construction of the connector unit as per the present subject matter ensures that the electrical connections of power line to any control device can be safely made without compromising on ease of establishing the electrical connections. Eliminating the use of individual couplers to connect the power lines to the control device ensures ease of assembly and ease of establishing electrical connections for the control device. As a result, assembly time involved in establishing electrical connections for the control device is also minimised.

[00016] Various other features and advantages of the invention are described in detail below with reference to the accompanying drawings. In the drawings, like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.

[00017] Fig.l is a top view of the connector unit 100 as per an embodiment of the present subject matter. As per an aspect of the present subject matter, and as may be seen in Fig.l, the connector unit 100 comprises a connector base 101 for holding two or more power lines 201 emerging from a wiring harness 200. In other words, the connector unit 100 is configured to house or accommodate at least a portion of the wiring harness including two or more power lines 201 to be electrically connected to a control device 400 (shown in Fig.4). In the present embodiment, the control device 400 is a motor control unit. The control device 400 as per the present embodiment receives five power lines for establishing electrical connection with a battery unit (not shown) and a motor unit (not shown). Particularly, as per the present embodiment, the control device 400 receives two power lines comprising positive and negative wires from the battery unit and three output power lines for powering the motor unit. Thus, in the present embodiment, five power lines are to be connected to the control device. As may be seen, each power line of the two or more power lines 201 is connected with a corresponding terminal member 202 each. In the present embodiment, each corresponding terminal member 202 of each power line 201 is a ring shaped. Alternatively, the profile o the terminal member can be of different geometry.

[00018] In order to house or accommodate each corresponding terminal member 202 fitted to each power line 201, the connector unit 100 comprises corresponding terminal slots 102, wherein each corresponding terminal slot 102 receives a corresponding terminal member 202 of each power line, and wherein the geometrical profile of the corresponding terminal slots 102 conforms to the profile of the terminal member. Particularly, as per an embodiment, the connector base 101 of connector unit 100 is integrally extended to form the two or more corresponding terminal slots 102. Particularly, said corresponding terminal slots 102 are formed in a manner such that each terminal slot 102 is at a predefined distance from the neighboring terminal slot 102, so that each power line of the two or more power lines 201 is held at a predefined distance from the neighboring power line. Further, in an additional embodiment and as may be seen, the connector unit 100 integrally includes a plurality of holder arms 103, wherein a pair of holder arms each of the plurality of holder arms 103 extends on either side of each terminal slot of the two or more corresponding terminal slots 102. When each power line of the two or more power lines 201 connected to a terminal member each is located in each terminal slot of the two or more corresponding terminal slots 102, a pair of crimped terminal arms 202a (shown in Fig.3) formed in each terminal member attached to each power line is pressed against each pair of holder arms. Thus, each power line is secured in each corresponding terminal slot of the two or more corresponding terminal slots 102 of the connector unit 100 and is prevented from moving even due to vehicle vibration. Further, in an additional embodiment a plurality of cable ties 104 are provided along a peripheral length of the connector base 101 on one side, with at least one cable tie securing each power line of the two or more power lines 201. Provision of the plurality of cable ties 104 also helps in preventing movement of the power lines. Further, in order to additionally ensure that two or more power lines 201 do not get damaged even during transit, the connector unit 100 is locked with a connector guide cum cover member 105 as per an embodiment of the present subject matter. The additional embodiments of incorporating an additional cable tie and / or the holder arms may be more beneficially implemented when the orientation of the assembly is at an angle to the ground making it more secure thereby achieving the purpose of a secure, reliable & safe electrical connections with ease of assembly.

[00019] Fig.2 illustrates an exploded perspective view depicting the connector unit and the connector guide cum cover member in accordance with an embodiment of the present subject matter. As may be seen, the connector guide cum cover member 105 includes a plurality of ribs 106 formed along a length of one surface of the connector guide cum cover member 105. Additionally, the connector guide cum cover member 105 integrally includes a plurality of guides 107, wherein a guide each is formed at a base of each rib of the plurality of ribs 106, and wherein a portion of each guide extends laterally outwards in the form of arms 107a from each rib of said plurality of ribs 106. While the guides 107 ensure precise location of the connectors in a sub-assembly station, the arms 107a are of a height dimension smaller that the height of the guide 107 thereby enabling offset disposition of the connectors on the connector unit since the connector are typically flat with low thickness as against the power lines which are circular with higher thickness. This ensure that the connector is held in their nominal position offset from any of the circumferentially contacting surfaces of the power lines & additionally ease the removal of the guide member from the connectors to be able to flip it as a cover member. Without the arms 107a the connectors can get stuck onto the guides making it difficult for the operator to swiftly flip the guide cum cover member from one side to other. The guide cum cover member in an additional embodiment is configured with additional ribs to couple with locking opening on the connecter unit when it has been flipped to function as a cover. As per an additional embodiment, the additional ribs on the guide cum cover member are also configured with arms similar to the arms on the guide 107a which help in maintaining an offset abutting contact between the cover & the connector unit. Further, the connector guide cum cover member 105 includes two or more locking arms 108 formed along its peripheral edges for locking with corresponding locking lugs 110 formed along corresponding peripheral edges of the connector base 101.

[00020] Fig.3 illustrates an exploded perspective view to depict the direction of assembly of the connector guide cum cover with the connector unit. During transit of the wiring harness 200 comprising two or more power lines 201 to be connected to the control device 500, the two or more power lines 201 are housed in the connector unit 100 by being disposed in the two or more corresponding terminal slots 102. In order to ensure that there is no damage to the corresponding terminal members of each power line of the two or more power lines 201, the connector unit 100 is locked with the connector guide cum cover member 105 on its bottom side. Particularly, during assembly the surface of the connector guide cum cover member 105, containing the plurality of ribs 106, faces the bottom side of the connector unit 100. Provision of the connector guide cum cover member 105 on the bottom side of the connector unit 100 allows the corresponding terminal member of each power line to be located on each rib of the plurality of ribs 106 and be completely covered on its rear side. Additionally, presence of the plurality of guides 107 including the arms 107a extending from each rib of the plurality of ribs 106 ensures that the corresponding terminal member 202 of each power line does not get entangled at the base of each rib and instead rests on the arms 107a extending on either side of each rib. As a result, when the connector unit 100 is unlocked from the connector guide cum cover member 105 after transit for connection of the two or more power lines 201 with the control device 400 (shown in Fig.4), the two or more power lines 201 along with their corresponding terminal members 202 can be easily disassembled from the plurality of ribs 106 formed on the connector guide cum cover member 105 without undergoing any damage.

[00021] Once the connector guide cum cover member 105 is dismantled from the connector unit 100, the connector unit 100 along with the two or more power lines 201 secured therein is carried to the control device 400. In other words, the wiring harness 200 including the two or more power lines 201 secured in the connector unit 100 and for connection with the control device 400 is carried to the control device 400. For example, Fig.4 illustrates a frame structure 410 of a two-wheeled saddle-type vehicle provided with a control device 400. In the present embodiment, the control device 400 is a motor control unit that controls the power supplied to a motor unit (not shown) from a battery unit 412. Further, in the present embodiment, the control device 400 is supported on a cross member 411 of the frame structure 410 and is disposed vertically besides the battery unit 412. Particularly, the corresponding terminals (not shown) of the control device 400 for connection with the two or more power lines 201 of the wiring harness 200 which in turn is also connected to the battery unit 412 and the motor unit (not shown) face towards a front region of the frame structure 410. The wiring harness

200 comprising the connector unit 100 is assembled on the control device 400 by connecting the two or more power lines 201 of the wiring harness 200 and secured in the connector unit 100 to the corresponding terminals (not shown) of the control device 400. In the present embodiment, the wiring harness 200 comprises five power lines to be connected to the corresponding terminals of the control device 400, out of which two power lines are connected as output from the battery unit 412 and three power lines are connected as input to the motor control unit 400. Particularly, in the present embodiment, the two or more power lines 201 are connected to the corresponding terminals of the control device by fastening the two or more corresponding terminal members 202 of the two or more power lines

201 with the corresponding terminals of the control device 400. Thus, the connector unit 100 that houses the two or more power lines 201 to be connected to the control device 400 is directly assembled over the control device 400. Therefore, the steps of accessing the power lines to be connected to the control device and that of routing the power lines etc. are eliminated and assembly time is considerably reduced. Moreover, ease of assembly is also ensured.

[00022] Once the two or more power lines 201 secured in the connector unit 100 are fastened to the corresponding terminals of the control device 400, the connector guide cum cover member 105 is located over the top surface of the connector unit 100 (see Fig.5), over the two or more power lines 201 secured therein. Particularly, while locating the connector guide cum cover 105 over the connector unit 100 which has been assembled over the control device 100, it is ensured that the other surface of the connector guide cum cover member 105 without the plurality of ribs 106 faces the outside towards a front portion of the frame structure 410. Once the other surface of the connector guide cum cover member 105 is placed over the top surface of the connector unit 100, the connector guide cum cover member 105 is pressed to be locked with the connector unit 100. Further, in the present embodiment a fastener 112 is also used to fasten the connector guide cum cover member 105 to the connector unit 100. A corresponding mounting hole 113 is formed in the connector unit 100 for receiving the fastener 112. Thus, in the assembled condition of the connector unit 100 over the control device 400, the guide cum cover member 105 serves as a protective cover for each corresponding terminal member of the two or more corresponding terminal members 202 of the two or more power lines 201. The guide cum cover member 105 helps prevent water and dust from entering into or directly splashing onto the two or more corresponding terminal members 202.

[00023] As can be made out from the teachings of the present subject matter, the configuration of the connector unit and the wiring harness comprising the connector unit is unique, wherein the connector unit housing different power lines can be directly used to establish electrical connection with any control device without the need for making individual connections. The teachings of the present subject matter offer a reliable solution for ensuring ease of establishing electrical connections for the control device without compromising on safety of the control device and that of the appliance/product employing the control device.