Method for manufacturing an assembly

Abstract

Method for manufacturing an assembly (1) comprising a component (2), a sensor receptacle (3) pressed into the component (2) and a sensor (4) screwed into the sensor receptacle (3), wherein a pre-assembly group (6) is formed by screwing the sensor (4) into the sensor receptacle (3) with a defined torque and the pre-assembly group (6) having the sensor receptacle (3) with the pre-assembled sensor (4) is pressed into the component (2) in a defined press-in orientation of the sensor (4).

Description

[0001] The invention relates to a method for manufacturing an assembly comprising a component, a sensor receptacle pressed into the component and a sensor screwed into the sensor receptacle.

[0002] Such assemblies and methods for manufacturing them are generally known from the prior art. Typically, the component, for example an air filter box or an engine housing, is provided, in whose wall a sensor is to be installed. For this purpose, a sensor receptacle, for example a metal insert, is pressed into the component. Specifically, if a thread cannot be directly integrated into the component, particularly with injection-molded plastic components, the appropriate threaded receptacle must be created separately. The sensor receptacle has an internal thread. The sensor, which has a corresponding external thread, is then screwed into the internal thread of the sensor receptacle. A sealing device, for example an O-ring, is usually arranged on the sensor, which seals the sensor receptacle when the sensor is screwed in.

[0003] It is further known that the sensor must be screwed into the sensor receptacle with a defined torque to ensure that the sealing device provides a sufficient seal. Since the sensor receptacle is pressed into the component in any orientation, and the threads on both the sensor receptacle and the sensor are arbitrarily oriented, and due to the comparatively high tolerances of the sealing device in response to screwing the sensor into the receptacle to achieve the required torque, no positional orientation or orientation, for example of the sensor, is guaranteed.

[0004] This means that across different manufactured assemblies, the sensor's orientation on the component or sensor mount can assume any value or position. This necessitates, firstly, that the connector plugged into the sensor be rotatable or flexible in relation to the sensor's orientation. This is achieved, for example, with a rotatable connector, which is more complex than a rigid connector.

[0005] Furthermore, the correct mounting of the sensor or the connector element attached to the sensor is typically monitored during the assembly manufacturing process, usually by means of a camera. This can be achieved, for example, by automatically detecting the correct insertion of the connector element. Depending on the specific orientation of the sensor, this may result in an orientation of the connector element that cannot be automatically detected by the camera. The same applies to additional information provided on the sensor, such as information to identify the sensor type. Since automated detection cannot provide any information about the condition of the assembly in this case, manual inspection or rework is usually necessary. This leads to a comparatively high rate of re-inspection, even though the assemblies are manufactured correctly.On the other hand, providing the threads for the sensor mount and sensor in a position-oriented manner also represents a significant effort. Furthermore, due to the high tolerance of the sealing device, it cannot be guaranteed at which rotation of the sensor in the sensor mount the defined torque is reached.

[0006] The invention is based on the objective of providing an improved method for manufacturing an assembly that is less costly, particularly with regard to rework and the components used.

[0007] The problem is solved by a method according to claim 1. The dependent claims relate to possible embodiments.

[0008] As described, the invention relates to a method for manufacturing an assembly. In its assembled state, the assembly comprises a component, for example a housing, a cable, or the like, and a sensor receptacle pressed into the component, as well as a sensor screwed into the sensor receptacle. As previously described, during the execution of the method, the assembly is manufactured, i.e., the individual parts of the assembly are provided and connected to one another, in particular by pressing the sensor receptacle into the component and screwing the sensor into the sensor receptacle.

[0009] The invention is based on the understanding that a pre-assembly group is formed by screwing the sensor into the sensor receptacle with a defined torque, and that the pre-assembly group, comprising the sensor receptacle with the pre-mounted sensor, is pressed into the component with a defined press-fit orientation of the sensor. The invention thus proposes a procedure that differs from the previously described, known prior art, in which the pre-assembly group is formed first, and then the entire pre-assembly group is pressed into the component. A defined press-fit orientation is established, which can be based on an orientation of the sensor, for example, relative to the component or any other direction. The pre-assembly group is pressed into the component with the defined press-fit orientation.

[0010] Advantageously, this ensures that, in the manufactured state of the assembly, the sensor points in a defined direction or is positioned correctly within the assembly. This is achieved primarily by first screwing the sensor into the sensor holder with a defined torque. Regardless of any tolerances in the sealing device, this results in a largely arbitrary orientation between the sensor and the sensor holder. Since the pre-assembly group, which includes the sensor holder and the sensor screwed into it, is then pressed into the component in a positionally oriented manner, it can be ensured that the sensor is always positioned in the desired direction or orientation within the assembly across all sub-assemblies.

[0011] This ensures that the subsequent inspection process following assembly can be carried out correctly, as the assembly feature to be inspected can always be automatically detected by the detection device, for example, a camera. This significantly reduces the effort required for rework or re-inspection, since each assembly can be detected by the detection device, thus ensuring whether it has been manufactured correctly and is therefore acceptable, or whether it requires rework because it is defective. In other words, cases where assemblies were manufactured correctly but cannot be automatically inspected due to an unfavorable sensor orientation are eliminated. Re-inspection and rework are therefore limited to assemblies that are actually defective.

[0012] Furthermore, it is advantageous that the threads on the sensor mount and on the sensor itself can be designed in virtually any way, meaning they do not need to have a specific orientation relative to each other. Additionally, the sealing device can also be designed in any way and have any tolerance, since the press-fit alignment is based on the pre-assembly group in which the sensor is already screwed into the sensor mount under the defined torque; that is, the tolerance regarding the threads and the sealing device is already taken into account.

[0013] In a further development of the method, it can be provided that the defined press-fit orientation is determined based on the position of at least one detent element of the sensor, in particular that the pre-assembly group is pressed in with a detent element pointing in the defined press-fit orientation. As described, the defined press-fit orientation can, in principle, be chosen arbitrarily, specifically based on a subsequent detection process by a detection device. Depending on which feature the detection device detects on the assembly, the defined press-fit orientation under which the pre-assembly group is pressed into the component can be determined. In the described embodiment, the subsequent detection process can verify the correct engagement of a detent element of the sensor. The press-fit orientation is therefore selected such that the detent element is subsequently pressed into the component.A locking element that engages with the locking element can be automatically detected by the detection device.

[0014] This means that when the pre-assembly group is pressed into the component with the defined press-fit orientation, the locking element is in a fixed position, for example, perpendicular to the detection direction of the detection device. Since the position-oriented press-fit of the pre-assembly group ensures that the locking element is in the fixed position across all assemblies, it is simultaneously guaranteed that this can subsequently be detected by the detection device.

[0015] In a further embodiment of the method, the pre-assembly group can be gripped and pressed in by means of at least one gripping device, wherein the gripping device has a counter contour corresponding to a contour of the pre-assembly group. Advantageously, the defined press-in orientation can then be set via the gripping device. A positional orientation between the gripping device and the pre-assembly group is established via the contour of the pre-assembly group and the corresponding counter contour of the gripping device. The gripped pre-assembly group can then be pressed into the component in the defined press-in orientation.

[0016] For example, the gripping device can have a receptacle for the sensor's locking element or for at least one of the sensor's locking elements. The gripping device can, for example, be part of a press tool. In particular, the sensor receptacle, for example a metal insert, is cold-pressed into the component, which can be made of or comprise plastic. The sensor receptacle pressed into the component seals the component, specifically through the pressing process and / or, for example, with an additional sealing device.

[0017] The method may further provide that a connector element is plugged into a sensor terminal of the sensor, the connector element having at least one locking element corresponding to the at least one latching element. As described, the sensor is then connected to the connector element after the pre-assembly assembly has been pressed in. The connector element connects the sensor, for example, electrically to a control device or any other device. The connector element has a locking element that corresponds to the at least one latching element of the sensor. The locking element can, for example, be designed as a locking tab.

[0018] If the connector element is correctly mounted or plugged into the sensor, the locking element engages with the locking element, or vice versa, or the locking element overlaps the locking element. The orientation of the locking element thus indicates whether the connector element is fully inserted onto the sensor connection or whether the connection between the connector element and the sensor connection is incomplete. In the latter case, the locking element rests, for example, on the locking element, allowing the detection device to recognize this based on the locking element's orientation. Because the locking element and locking element are positioned in a defined location on the assembly—namely, due to the defined press-fit orientation of the pre-assembled component—it is ensured that both the locking element and the locking element can always be detected by the detection system.

[0019] Furthermore, the method can include the detection of the locking state of the locking element after the connector element is inserted, particularly by means of a detection device. As described, pressing in the pre-assembly group in the defined press-fit orientation ensures that the sensor, in the assembled state of the assembly, has a defined orientation in space, for example, relative to the component or the detection device. This also ensures that the locking element and the locking element of the connector element, which engages with the locking element, are aligned in a defined manner.

[0020] Therefore, in a process step downstream of assembly, a detection device, such as a camera, can be provided to capture the assembly, in particular the locking status of the connector element's locking mechanism. The locking mechanism can, for example, have an initial orientation during the insertion of the connector element into the sensor receptacle or onto the sensor's sensor port, and a second orientation upon complete assembly. If the connector element is correctly inserted, the locking mechanism can, for example, snap onto the locking element, thus transitioning from its first to its second orientation. By capturing the second orientation with the detection device, the assembly of the component can be verified.If the initial orientation is confirmed, a defect exists in the insertion of the connector element, meaning the assembly can be reworked. Advantageously, because the defined press-fit orientation is ensured, a simpler detection device, for example with fewer cameras or fewer detection angles, can be used.

[0021] As described at the outset, due to the lack of orientation control, connector elements that are rotatable are typically used for such assemblies in the prior art. This means that the cable exit of the connector element is movably arranged on the part of the connector element that is plugged into or attached to the sensor connection. In a further development of the method, it is possible to use an orientation-fixed connector element, particularly one with a rigid cable exit, as the connector element to be plugged into the sensor connection. Since the pre-assembly group always has the same orientation relative to the component, and thus the sensor also always has a fixed orientation across all manufactured assemblies, it is not necessary to use such complex movable connector elements. Instead, a simpler orientation-fixed connector element, particularly one with a rigid cable exit, can be used.This is not possible with the previously described, state-of-the-art assemblies, since the sensor and its sensor connection can have any orientation across all assemblies, which must be compensated for by the plugged connector element.

[0022] The method can further provide that at least one piece of information, in particular identification information, is arranged on the sensor in a defined detection orientation and is detected by at least one detection device. In other words, information, for example, identification information, can be provided on the sensor. If the sensor is arranged in the pre-assembly group and attached to the component by means of the pre-assembly group, as described above, the information is present in the detection orientation and can therefore be detected by the detection device. The identification information is, for example, a sequential serial number or a type identifier of the sensor. The detection device can therefore be used to verify the correct orientation and correct assembly of the connector element, and furthermore, it can be verified that the correct sensor has been installed in the assembly.

[0023] In a further embodiment of the method, the sensor can be detachably screwed into the sensor holder. As described, the sensor is screwed into the sensor holder, and the resulting pre-assembled unit is then pressed into the component in the defined press-fit orientation. This means that the sensor can subsequently be unscrewed from the sensor holder.

[0024] In the event of service or maintenance, the sensor can be unscrewed if necessary. This creates a detachable connection between the sensor and the sensor housing by screwing the sensor into the housing with the torque described above. If the sensor subsequently needs to be removed, for example, due to a defect, it can be unscrewed from the housing. During maintenance, this allows the sensor to be easily removed from the housing, particularly without damage, and replaced with a new sensor, for example.

[0025] As described at the beginning, the assembly can generally be designed for any component, or any component can be provided, into which the sensor mount can be pressed. Specifically, the component of the assembly is made of plastic or comprises at least one plastic component. The sensor mount can specifically be a metal insert that provides a thread, for example, an internal thread, for a corresponding thread, for example, an external thread, on the sensor.

[0026] In one embodiment, the pre-assembly group can be pressed into a motor housing and / or a media-carrying container and / or a media-carrying line. The sensor can be any type of sensor. The sensor is specifically designed to transmit the pressing forces during the insertion of the pre-assembly group into the component. The sensor can be, for example, a pressure sensor, temperature sensor, gas sensor, flow sensor, rotor sensor, voltage sensor, current sensor, level sensor, and the like. For example, the sensor can be a speed sensor, a rotor position sensor, or a sensor designed to determine a gas concentration. The media-carrying container or line can be, for example, a water tank, a water line, an oil line, an air filter housing, an oil module, and the like.

[0027] In addition to the method, the invention relates to a device for manufacturing an assembly comprising a component, a sensor receptacle pressed into the component, and a sensor screwed into the sensor receptacle. The device is configured to form a pre-assembly group by screwing the sensor into the sensor receptacle with a defined torque and to press the pre-assembly group, comprising the sensor receptacle with the pre-assembled sensor, into the component in a defined press-in orientation of the sensor. The device can be used, in particular, to carry out the method described above. In other words, the method described above can be carried out with the device described herein.

[0028] All advantages, details, designs and / or features described in relation to the method are fully transferable to the device.

[0029] The invention is explained with reference to exemplary embodiments and the figures. The figures are schematic representations and show: Fig. 1 a schematic representation of a first process step of a process for manufacturing an assembly according to an exemplary embodiment; Fig. 2 a schematic representation of a second process step of a process for manufacturing an assembly according to an exemplary embodiment; Fig. 3 a schematic representation of a third process step of a process for manufacturing an assembly according to an exemplary embodiment; Fig. 4 a schematic representation of a fourth process step of a method for manufacturing an assembly according to an exemplary embodiment when assembled correctly; and Fig. 5 A schematic representation of a fourth process step of a method for manufacturing an assembly according to an exemplary embodiment in the case of incorrect assembly.

[0030] Fig. Figure 1 shows an example of a first process step for manufacturing an assembly 1. The assembly 1 comprises a component 2, which is, for example, a medium-carrying component 2, such as an air filter box, an oil module, a line, or the like, or an engine housing. The medium can be, for example, air or oil, carried in the component 2. The assembly 1 further comprises a sensor receptacle 3, which is to be pressed into the component 2. The sensor receptacle 3 has a thread, for example, an internal thread, which corresponds to a thread, for example, an external thread, of a sensor 4 of the assembly 1.

[0031] The sensor 4 has a sealing device 5 designed to seal an interior space of the component 2 from the environment when the sensor 4 is mounted on the component 2 together with the sensor receptacle 3. In other words, the sensor 4 can be screwed into the sensor receptacle 3. When screwed into the sensor receptacle 3, the sealing device 5 is pre-tensioned against the sensor receptacle 3, thus achieving a sealing effect.

[0032] Instead of first pressing the sensor mount 3 into the component 2, as in Fig. As shown in Figure 2, a pre-assembly group 6 is first produced by screwing the sensor 4 into the sensor holder 3 before pressing the sensor holder 3 into the component 2. The sensor 4 is screwed into the sensor holder 3 with a defined torque. Accordingly, the orientation between the sensor 4 and the sensor holder 3 is fixed in the pre-assembly group 6. Positional deviations resulting from the individual threads in the sensor holder 3 and on the sensor 4, or resulting from the compression of the sealing device 5 when the defined torque is applied, are therefore already accounted for in the pre-assembly group 6.

[0033] Starting from the second process step, which is in Fig. As shown in 2, the state is reached that is shown in Fig. 3 is shown, in which the pre-assembly group 6 (see Fig. 2) is pressed into component 2, namely in a defined press-fit orientation of the sensor 4. In this embodiment, the defined press-fit orientation of the sensor 4 or the pre-assembly group 6 is determined such that one or two locking elements 7 are in a specific locking element position. As shown, the locking element position and thus the press-fit orientation can be selected relative to component 2 or relative to any other reference point, for example, relative to a detection device not shown.

[0034] In any case, it can be ensured that the locking elements 7 can subsequently be detected by a detection device. Furthermore, identification information, or more generally, information such as a serial number, type, barcode, QR code, or the like, can be applied to the sensor 4 in such a way that it can be detected by the detection device after the pre-assembly group 6 has been pressed in the defined press-fit orientation. The detection device can, for example, detect the assembly 1 within the plane of the markings, or vice versa.

[0035] Furthermore, in Fig. Figures 1-5 show that the sensor 4 includes a sensor connection 8. The sensor connection 8 allows the sensor 4 to be connected to a connector element 9, for example by inserting or attaching the connector element 9, which is located in Fig. 3-5 is shown. In the process step that is in Fig. As shown in Figure 3, the connector element 9 is not yet attached to or inserted into the sensor connection 8. Since, as previously described, the pre-assembly group 6 is pressed into the component 2 in a defined press-fit orientation, the sensors 4, and thus also the sensor connections 8, are in a fixed orientation across all manufactured assemblies 1. The connector element 9 can therefore be designed as a position-fixed or orientation-fixed connector element 9. In particular, the connector element 9 has a rigid cable exit 10. This allows the connector element 9 to be designed in a less complex and simplified manner.

[0036] In Fig. 3, Fig. Figure 5 further shows that the connector element 9 has at least one locking element 11, for example, two locking elements 11 for the two locking elements 7. When the connector element 9 is plugged onto or inserted into the sensor connector 8, the locking elements 11 engage with the locking elements 7 when the plugging of the connector element 9 is fully completed. Fig. Figure 4 shows an example of the complete assembly of the connector element 9 onto the sensor connection 8. If, however, the connector element 9 is not fully attached to or inserted into the sensor connection 8, the situation arises that is illustrated in the example. Fig. 5 is shown.

[0037] In other words, a detection device can detect, either into or out of the drawing plane, whether the locking elements 11 are in a predefined locking state, for example, fully latched. If this is the case, the assembly 1 can be assessed as OK ( Fig. 4) If the situation is in Fig. If 5 is the time before, assembly 1 can be subjected to rework.

[0038] Advantageously, it is therefore not necessary to subject assemblies 1, which have been fully assembled and are therefore in order, to a subsequent inspection or rework, because the locking elements 7 and the locking elements 11 cannot be automatically detected. Instead, the position-oriented arrangement of the pre-assembly group 6 in the component 2 ensures that the locking elements 7 and the locking elements 11 can always be detected.

[0039] This can also be ensured, for example, by gripping the pre-assembly group 6 with a gripping device that has a counter contour corresponding to the contour of the pre-assembly group 6 and pressing it into the component 2 in the defined press-fit orientation.

[0040] In assembly 1, it is further ensured that sensor 4 can be detached again after assembly. For example, the connector element 9 can be disconnected or pulled off the sensor connection 8. The sensor 4 can then be unscrewed from the sensor housing 3. The sensor thus remains detachable in the described configuration, so that, for example, removing or replacing sensor 4 remains possible in the event of service or maintenance.

[0041] The described method can be carried out using a device for manufacturing assembly 1. The device is suitable for carrying out the described method in all details and with all features. In particular, the device has a screwing device designed to screw the sensor 4 into the sensor receptacle 3 with the defined torque. Furthermore, the device has a press-fit device designed to press the manufactured pre-assembly group 6 into the component 2 in the defined press-fit orientation. In particular, the pre-assembly group 6 is cold-pressed into the component 2. The component 2 is made of plastic or has a plastic section into which the pre-assembly group 6 is pressed. The sensor 4 is designed to transmit the forces transferred to the pre-assembly group 6 during pressing to the sensor receptacle 3.

[0042] The advantages, details and features described in the individual embodiments can be combined, interchanged and transferred to one another as desired. REFERENCE MARK LIST 1 assembly 2 components 3 Sensor recording 4 Sensor 5 Sealing device 6 Pre-assembly group 7 locking element 8 Sensor connection 9 connector element 10 Line outlet 11 Safety element

Claims

[1] Method for manufacturing an assembly (1) comprising a component (2), a sensor receptacle (3) pressed into the component (2) and a sensor (4) screwed into the sensor receptacle (3), characterized by , that a pre-assembly group (6) is formed by screwing the sensor (4) into the sensor receptacle (3) with a defined torque and the pre-assembly group (6) having the sensor receptacle (3) with the pre-assembled sensor (4) is pressed into the component (2) in a defined press-in orientation of the sensor (4). [2] Method according to claim 1, characterized by , that the defined press-in alignment is determined based on a detent element position of at least one detent element (7) of the sensor (4), in particular the pre-assembly group (6) is pressed in with a detent element (7) pointing into the defined press-in alignment. [3] Method according to claim 1 or 2, characterized by, that the pre-assembly group (6) is gripped and pressed in by means of at least one gripping device, wherein the gripping device has a counter contour corresponding to a contour of the pre-assembly group (6). [4] Method according to one of claims 2 or 3, characterized by , that a plug element (9) is plugged onto a sensor connection (8) of the sensor (4), wherein the plug element (9) has at least one locking element (11) corresponding to the at least one locking element (7). [5] Method according to claim 4, characterized by , that a secure state of the security element (11) is detected after the plug element (9) is inserted, in particular by means of a detection device. [6] Method according to claim 4 or 5, characterized by , that the plug element (9) to be plugged onto the sensor connection (8) is an orientation-fixed plug element (9), in particular with a rigid cable exit (10). [7] Method according to any of the preceding claims, characterized by , that at least one piece of information, in particular identification information, is arranged in a defined detection orientation on the sensor (4) and is detected by means of at least one detection device. [8] Method according to any of the preceding claims, characterized by , that the sensor (4) is releasably screwed into the sensor holder (3). [9] Method according to any of the preceding claims, characterized by , that the pre-assembly group (6) is pressed into a motor housing and / or a media-carrying container and / or a media-carrying line. [10] Device for manufacturing an assembly (1) comprising a component (2), a sensor receptacle (3) pressed into the component (2) and a sensor (4) screwed into the sensor receptacle (3), characterized by, that the device is designed to form a pre-assembly group (6) by screwing the sensor (4) into the sensor receptacle (3) with a defined torque and to press the pre-assembly group (6) comprising the sensor receptacle (3) with the pre-assembled sensor (4) into the component (2) in a defined press-in orientation of the sensor (4).

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