System of cable and connectors with integrated sensors

Abstract

An electrical connector assembly includes a first connector member, a second connector member configured for connection with the first connector member, a first insulator disposed at least partially in the first connector member and/or the second connector member, a second insulator disposed at least partially in the first connector member and/or the second connector member, and a circuit board configured to be disposed at least partially between the first insulator and the second insulator in a connected configuration of the electrical connector assembly. The circuit board may include an electrical characteristic sensor and/or a temperature sensor.

What is claimed is: 
     
         1 . An electrical connector assembly, comprising:
 a first connector member;   a second connector member configured for connection with the first connector member;   a first insulator disposed at least partially in the first connector member and/or the second connector member;   a second insulator disposed at least partially in the first connector member and/or the second connector member; and   a circuit board configured to be disposed at least partially between the first insulator and the second insulator in a connected configuration of the electrical connector assembly; and   an electrical characteristic sensor electrically connected with the circuit board.   
     
     
         2 . The electrical connector assembly of  claim 1 , wherein the electrical characteristic sensor includes a voltage sensor and/or a current sensor. 
     
     
         3 . The electrical connector assembly of  claim 1 , wherein the circuit board includes a current loop. 
     
     
         4 . The electrical connector assembly of  claim 3 , including an electrical terminal;
 wherein the current loop is electrically connected to the electrical terminal to provide an electrical connection between a conductor connected to the electrical terminal and the electrical characteristic sensor such said conductor may provide power to the electrical characteristic sensor.   
     
     
         5 . The electrical connector assembly of  claim 1 , including a temperature sensor disposed at least partially in the first connector member and/or the second connector member. 
     
     
         6 . The electrical connector assembly of  claim 1 , wherein the first connector member is configured for connection with a first cable; and
 the second connector member is configured for connection with a second cable.   
     
     
         7 . The electrical connector assembly of  claim 6 , wherein the circuit board is configured for electrical connection with a conductor of the first cable to provide power to the electrical characteristic sensor. 
     
     
         8 . The electrical connector assembly of  claim 1 , wherein the circuit board is connected to the first insulator and the second insulator via an adhesive. 
     
     
         9 . The electrical connector assembly of  claim 1 , wherein, in a connected configuration, the circuit board is disposed radially within portions of the first connector member and the second connector member. 
     
     
         10 . The electrical connector assembly of  claim 1 , including an electrical terminal;
 wherein the electrical terminal is disposed in the first insulator and the circuit board.   
     
     
         11 . The electrical connector assembly of  claim 10 , wherein the electrical terminal extends through the circuit board. 
     
     
         12 . The electrical connector assembly of  claim 1 , wherein the first insulator includes a first portion and a second portion;
 the circuit board is disposed at least partially between the first portion and the second portion; and   in a connected configuration, the circuit board and the second portion are disposed at least partially between the first portion and the second insulator.   
     
     
         13 . An electrical system, comprising:
 a cable;   a first electrical connector assembly connected to a first end of the cable, the first electrical connector assembly including a first electrical characteristic sensor and a first temperature sensor;   a second electrical connector assembly connected to a second end of the cable, the second electrical connector assembly including a second electrical characteristic sensor and a second temperature sensor; and   an electronic control unit (ECU) connected to the first electrical characteristic sensor, the first temperature sensor, the second electrical characteristic sensor, and the second temperature sensor;   wherein the ECU is configured to determine a leakage current according to a difference between a first current sensed via the first electrical characteristic sensor and a second current sensed via the second electrical characteristic sensor.   
     
     
         14 . The electrical system of  claim 13 , wherein the cable includes a plurality of conductors;
 a respective resistor is connected in series with each of the plurality of conductors; and   each respective resistor includes a unique resistance to facilitate identification of conductors of the plurality of conductors.   
     
     
         15 . The electrical system of  claim 14 , wherein at least one of the plurality of conductors is electrically connected with the first electrical characteristic sensor to provide power to the first electrical characteristic sensor. 
     
     
         16 . The electrical system of  claim 15 , wherein the at least one of the plurality of conductors is electrically connected with the second electrical characteristic sensor to provide power to the second electrical characteristic sensor. 
     
     
         17 . The electrical system of  claim 13 , wherein the cable includes a plurality of conductors; and the first electrical characteristic sensor is connected to a first conductor of the plurality of conductors to provide a sensor signal to the ECU. 
     
     
         18 . The electrical system of  claim 13 , wherein the first electrical characteristic sensor includes a first current sensor and a first voltage sensor. 
     
     
         19 . The electrical system of  claim 13 , wherein the ECU is configured to detect an error if a first temperature sensed via the first temperature sensor is outside of a specified or predetermined range; and
 the ECU is configured to disable an electrical component connected to the cable if the ECU detects the error.   
     
     
         20 . A method of operating an electrical system including an electrical connector assembly and a cable, the method comprising:
 sensing an electrical characteristic and/or a temperature associated with the cable via an electrical characteristic sensor and/or a temperature sensor connected to a circuit board of the electrical connector assembly;   comparing, via an electronic control unit (ECU), the sensed electrical characteristic and/or temperature with a specified or predetermined range; and   detecting an error if the sensed electrical characteristic and/or temperature is outside the specified or predetermined range.