Ultrasonic sensor and method for assembling the same

Abstract

To improve assembly efficiency and product yield of an ultrasonic sensor.SOLUTION: An ultrasonic sensor is provided, comprising: a sensor including a plurality of front cover clamping parts arranged at unequal intervals along a circumference; a front cover including a plurality of sensor clamping parts to be clamped with the front cover clamping parts; and a terminal seat including a terminal seat body forming a front opening and an accommodating space configured to be in communication with the front opening and accommodate at least a part of the sensor, and a connecting terminal configured in the accommodating space.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention provides an ultrasonic sensor and an assembling method for an ultrasonic sensor, and in particular, an ultrasonic sensor having components therein and an assembling method for an ultrasonic sensor that is applicable to assembling the ultrasonic sensor. [Background technology]

[0002] Automobiles are an essential means of transportation in people's lives. To prevent collisions with other vehicles or obstacles while driving or backing up, ultrasonic sensors that can detect the distance between the vehicle and other vehicles or obstacles are typically installed around the vehicle. Non-contact detection technologies, such as ultrasonic and optical sensing, can also inform the driver of safe distances in real time while driving or backing up, preventing damage to the vehicle and the resulting safety issues. Summary of the Invention [Problem to be solved by the invention]

[0003] Taking an ultrasonic sensor as an example, the radar may include a sensor (transducer) that transmits and receives ultrasonic signals, a front cover that protects the sensor from collisions with external objects or the intrusion of foreign matter (e.g., rain or snow), and a terminal block that houses the sensor. When assembling a radar, the sensor and front cover are typically moved from the front to the rear of the terminal block until they reach their designated positions. However, if other components (e.g., connection terminals) are provided within the housing space, automated assembly is currently possible on the market, but this involves problems such as high costs and difficulty in developing the automation equipment, as well as the likelihood of misalignment during assembly.

[0004] In order to solve the above problems and to improve the assembly efficiency of ultrasonic sensors and the product yield, the inventors have conducted research and developed an ultrasonic sensor having internal components and an ultrasonic sensor assembly method for assembling the ultrasonic sensor. [Means for solving the problem]

[0005] The present invention provides an ultrasonic sensor. In one aspect, the present invention provides an ultrasonic sensor including: a sensor including a plurality of front cover locking portions arranged at uneven intervals along the circumferential direction; a front cover including a plurality of sensor locking portions that lock with the front cover locking portions; a terminal block including a terminal block main body having a front opening and an accommodating space that communicates with the front opening and accommodates at least a portion of the sensor; and a connection terminal arranged in the accommodating space.

[0006] In the above aspect, the connection terminal may be molded in advance within the accommodating space, or may be molded integrally with the terminal block body.

[0007] In the above aspect, at least one sensor positioning portion included in the terminal block main body may be engaged with at least one terminal block positioning portion further included in the sensor.

[0008] In the above aspect, the ultrasonic sensor may be an ultrasonic sensor assembled by a carrier having an assembly groove formed therein, the assembly groove including a front cover accommodating groove and a sensor accommodating groove recessed relative to the bottom of the front cover accommodating groove. Note that the sizes of the front cover and the sensor may correspond to the front cover accommodating groove and the sensor accommodating groove, respectively.

[0009] In the above aspect, the ultrasonic sensor may be assembled with a carrier including a limiting feature that interlocks with a limiting portion included in the terminal block body.

[0010] In addition, the present invention provides a method for assembling an ultrasonic sensor, including the steps of providing a carrier, a sensor, a front cover, and a terminal block; placing the front cover in an assembly groove of the carrier; engaging the front cover locking portions of the sensor, which are arranged at uneven intervals along the circumferential direction, with the sensor locking portions of the front cover; and accommodating at least a portion of the sensor, which is arranged at intervals from the connection terminals in the accommodation space, into the accommodation space of the terminal block through the front opening of the terminal block.

[0011] In the above aspect, the connection terminal may be molded in advance in the accommodating space, or may be molded integrally with the terminal block body of the terminal block.

[0012] In the above aspect, the method for assembling the ultrasonic sensor may further include engaging at least one terminal block positioning portion of the sensor and at least one sensor positioning portion of the terminal block with each other.

[0013] In the above aspect, the method for assembling the ultrasonic sensor may further include interlocking the restraining feature of the carrier and the restraining portion of the terminal block with each other. [Effects of the Invention]

[0014] Therefore, when assembling an ultrasonic sensor using the ultrasonic sensor assembly method of the present invention, the front cover locking portions can lock with the sensor locking portions, and because they are arranged at uneven intervals along the circumferential direction, it is possible to prevent parts from being installed out of alignment with each other during the automated assembly process, significantly improving assembly efficiency and product yield. Therefore, the ultrasonic sensor assembly method of the present invention is applicable to ultrasonic sensors having connection terminals arranged inside.

[0015] In order to make the above features and advantages of the present invention more comprehensible, the following embodiments are given and described in detail in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a perspective view of an ultrasonic sensor according to an embodiment of the present invention; [Figure 2] FIG. 2 is an exploded view of the ultrasonic sensor of FIG. 1. [Figure 3] FIG. 3 is a perspective view of the sensor body in FIG. 2. [Figure 4] FIG. 3 is a perspective view of the coupling member of FIG. 2. [Figure 5] FIG. 5 is a cross-sectional view of FIG. [Figure 6] FIG. 3 is a perspective view of the front cover in FIG. 2. [Figure 7] FIG. 3 is a plan view of the terminal block in FIG. 2. [Figure 8] FIG. 8 is a cross-sectional view taken along the line XX in FIG. 7. [Figure 9] FIG. 3 is a perspective view of the carrier in FIG. 2. [Figure 10] 3 is a flowchart of steps in one embodiment of a method for assembling an ultrasonic sensor of the present invention. [Figure 11] FIG. 10 is a cross-sectional view of a carrier provided according to step S100. [Figure 12] FIG. 10 is a cross-sectional view of the front cover being placed in the assembly groove in accordance with step S200. [Figure 13] FIG. 3 is a side view of the sensor in FIG. 2 after assembly is complete. [Figure 14] FIG. 10 is a cross-sectional view illustrating assembling the sensor and the front cover according to step S300. [Figure 15] FIG. 10 is a cross-sectional view illustrating the assembly of the sensor and the terminal block according to step S400. DETAILED DESCRIPTION OF THE INVENTION

[0017] The above and other technical contents, features, and advantages of the present invention will be clearly disclosed below by referring to preferred embodiments in conjunction with the drawings. It should be noted that the directional terms used in the following embodiments, such as up, down, left, right, front, and rear, are only directions in the accompanying drawings. Therefore, the directional terms used are used for explanation purposes only and are not intended to limit the present invention. Furthermore, in the following embodiments, the same or similar parts may be designated by the same or similar reference numerals.

[0018] Please refer to Figures 1 and 2. Figure 1 is a perspective view of an embodiment of an ultrasonic sensor of the present invention. Figure 2 is an exploded view of the ultrasonic sensor of Figure 1. The ultrasonic sensor 1 of this embodiment is, for example, an ultrasonic sensor, and is assembled using a carrier 2. During assembly, a single carrier 2 can be used, or, as shown in Figure 2, multiple carriers 2 can be used at once to assemble multiple ultrasonic sensors 1 simultaneously. In addition, the carrier 2 can be a fixed mold or a moving device installed on a production line, and the present invention does not impose any limitations thereon.

[0019] Meanwhile, the ultrasonic sensor 1 includes a sensor 100, a front cover 200, and a terminal block 300. The sensor 100 is, for example, an ultrasonic transducer used to transmit or receive ultrasonic waves and detect the distance between the vehicle on which it is installed and other nearby vehicles or obstacles. The front cover 200 is used in combination with the sensor 100 to prevent the sensor 100 from colliding with external objects or from being exposed to pollutants such as rain or snow. The terminal block 300 is used to house at least a portion of the sensor 100, and is used to install the sensor 100 and the front cover 200 on the vehicle and to transmit received signals to a user in the vehicle or to obtain electricity required for the sensor 100 to operate from the vehicle.

[0020] The sensor 100 preferably includes a sensor body 110 and a connecting member 120. The sensor body 110 is made of, for example, aluminum or aluminum alloy and is connected to the front cover 200 by the connecting member 120. The connecting member 120 is made of, for example, flexible silicone. That is, when assembling the sensor 100 and the front cover 200, the sensor body 110 and the connecting member 120 are first assembled, and then the connecting member 120 including the sensor body 110 is assembled to the front cover 200, thereby improving the connection efficiency of the sensor 100 and the front cover 200. However, in other embodiments, the sensor body 110 and the connecting member 120 may be a single, inseparable part. That is, the structure of the sensor 100 itself may be divided into a part used for detection and a part to be assembled with other parts, and the present invention does not impose any limitations thereon.

[0021] Please refer to Figure 3. Figure 3 is a perspective view of the sensor body in Figure 2. Specifically, the sensor body 110 may include a housing 112 and a coupling part 114. The housing 112 is, for example, a cylindrical housing, and the coupling part 114 is, for example, a component fixed to one end of the housing 112, with the housing 112 and the coupling part 114 forming a chamber 116. The chamber 116 can also be used to house a component that generates vibrations by electrical effect and transmits or detects ultrasonic signals.

[0022] Please refer to Figures 4 and 5. Figure 4 is a perspective view of the coupling member of Figure 2. Figure 5 is a cross-sectional view of Figure 4. Meanwhile, the coupling member 120 includes a coupling body 122, a plurality of front cover locking portions 124, and at least one terminal block positioning portion 126. The front cover locking portions 124 are arranged at irregular intervals along the circumferential direction of the coupling body 122. In this embodiment, the front cover locking portions 124 are, for example, recesses, three in number, formed on the upper, right, and lower sides of the coupling body 122 in Figure 4, and are used to engage and position the front cover 200 relative to the front cover 200 during assembly of the ultrasonic sensor 1. The terminal block positioning portions 126 are, for example, grooves further recessed from the bottom of the front cover locking portion 124, two in number, formed on the upper and lower sides of the coupling body 122 in Figure 4, and are used to engage and position the terminal block 300 relative to the front cover 200 during assembly of the ultrasonic sensor 1.

[0023] 5, the coupling body 122 is further formed with an accommodating groove 128, the shape and size of which correspond to the coupling portion 114. When the sensor body 110 and the coupling member 120 are coupled to each other, the coupling portion 114 is fitted into the accommodating groove 128, thereby enabling the sensor body 110 and the coupling member 120 to be tightly coupled to each other.

[0024] Please refer to Figure 6. Figure 6 is a perspective view of the front cover in Figure 2. In this embodiment, the front cover 200 is, for example, a ring-shaped part made of plastic, and includes a front cover main body 210 and a plurality of sensor locking portions 220. The sensor locking portions 220 are, for example, blocks whose shape and size correspond to the front cover locking portions 124. There are three of them, and they are arranged at uneven intervals around the circumferential direction of the front cover main body 210.

[0025] Please refer to Figures 7 and 8. Figure 7 is a plan view of the terminal block in Figure 2. Figure 8 is a cross-sectional view taken along the line XX in Figure 7. As shown in the drawings, the terminal block 300 includes a terminal block body 310 and connection terminals 320. The terminal block body 310 has an accommodating space 316 and a front opening 318. The accommodating space 316 is connected to the front opening 318. The connection terminals 320 are disposed in the accommodating space 316, with some of the connection terminals 320 penetrating the front opening 318. In this embodiment, the connection terminals 320 are, for example, pin feet used for electrically connecting with the sensing components of the sensor 100. The connection terminals 320 may be pre-formed (precast) in the accommodating space 316 or may be integrally formed (integrated) with the terminal block body 310 during the manufacturing process of the terminal block body 310. However, in other embodiments, it is only necessary to arrange a socket used to insert the connection terminal 320 inside the terminal block body 310, and the connection terminal 320 can be inserted into the socket, and the present invention does not impose any restrictions on this.

[0026] Preferably, the terminal block 300 further includes a connecting portion 330. The connecting portion 330 is, for example, a hollow base used for fixing and connecting to a vehicle. The connecting portion 330 is fixed to one end of the terminal block body 310, and its size and shape can be customized according to the vehicle or the installation location. A limiting portion 360 may also be formed between the terminal block body 310 and the connecting portion 330. In this embodiment, the limiting portion 360 is, for example, a link-shaped recess recessed into the surfaces of the terminal block body 310 and the connecting portion 330. The limiting portion 360 can be positioned by the limiting portion 360 and the carrier 2 during assembly of the ultrasonic sensor 1, and this portion will be described in detail below.

[0027] In some embodiments, the terminal block 300 may further include at least one auxiliary connection terminal 340. The auxiliary connection terminal 340 may be a pin foot or a connection pin similar to the connection terminal 320, and may be used to transmit electricity to the sensor 100 or to transmit a signal detected by the sensor 100 to a control unit inside the vehicle or connected in series with another sensor 100.

[0028] Please refer to FIG. 9. FIG. 9 is a perspective view of the carrier 2 in FIG. 2. The carrier 2 in this embodiment includes a carrier body 22, which may have an assembly groove 26 and an auxiliary assembly groove 28 formed therein. The assembly groove 26 is used to accommodate part of the terminal block 300, the front cover 200, and the sensor 100. The auxiliary assembly groove 28 is, for example, a shallow groove slightly recessed relative to the surface of the carrier body 22 and is used to assist in positional restriction during assembly of the ultrasonic sensor 1, thereby preventing the ultrasonic sensor 1 from moving or rotating relative to the carrier 2. In this embodiment, the carrier body 22 further has a limiting feature 24 formed between the assembly groove 26 and the auxiliary assembly groove 28. The limiting feature 24 is, for example, a rib whose size and shape correspond to the limiting portion 360 and is used to engage with the limiting portion 360.

[0029] Please refer to Figures 10 to 15. Figure 10 is a flowchart of steps in one embodiment of a method for assembling an ultrasonic sensor of the present invention. Figures 11 to 15 are corresponding views showing the steps of the method for assembling an ultrasonic sensor. As shown in Figure 10, the method for assembling an ultrasonic sensor of this embodiment includes the steps of providing a carrier, a sensor, a front cover, and a terminal block (step 100), placing the front cover in an assembly groove of the carrier (step 200), engaging the front cover locking portions of the sensor, which are arranged at irregular intervals along the circumferential direction, with the front cover locking portions of the front cover (step 300), and accommodating at least a portion of the sensor, which is arranged at intervals from the connection terminals in the accommodation space, into the accommodation space of the terminal block through the front opening of the terminal block (step 400).

[0030] As shown in Figure 11, a carrier 2 may be provided when assembling the ultrasonic sensor 1. The assembly groove 26 of the carrier 2 may include a front cover accommodating groove 26a, a front cover positioning groove 26b, and a sensor accommodating groove 26c. The size and depth of the front cover accommodating groove 26a correspond to the front cover 200. The front cover positioning groove 26b is, for example, a shallow, ring-shaped groove that is slightly recessed from the bottom of the front cover accommodating groove 26a. The sensor accommodating groove 26c is a deep groove that is recessed from the bottom of the front cover accommodating groove 26a and is located in the center of the front cover accommodating groove 26a. The size and depth of the sensor accommodating groove 26c correspond to the sensor 100.

[0031] 12, the front cover 200 may then be placed in the assembly groove 26. At this time, the outer edge of the front cover main body 210 and the peripheral wall of the front cover receiving groove 26a are flush with each other, and the front end of the front cover main body 210 is fitted into the front cover positioning groove 26b. It is preferable to form a convex or concave portion corresponding to the front end of the front cover main body 210 and the front cover positioning groove 26b, and having a directional configuration. In this way, when the front cover 200 is placed, the assembly direction of each ultrasonic sensor 1 can be maintained to be the same.

[0032] 13, the sensor body 110 and the coupling member 120 can be coupled together to make the sensor 100 suitable for assembly with the front cover 200. Specifically, the manufacturer can use a specialized machine to slightly expand the deformable coupling member 120, allowing the coupling portion 114 to fit into the receiving groove 128, thereby fixing the sensor body 110 and the coupling member 120 relative to each other.

[0033] 14, by placing the assembled sensor 100 in the assembly groove 26, the front cover locking portions 124 of the connecting member 120 and the sensor locking portions 220 of the front cover 200 can be locked together. Because the front cover locking portions 124 and the sensor locking portions 220 are all arranged at uneven intervals along the circumferential direction, a mistake-proofing effect can be achieved during assembly, preventing misalignment between the sensor 100 and the front cover 200 and improving the efficiency and accuracy of automated assembly.

[0034] 15 , after the sensor 100 and the front cover 200 are assembled and positioned, the terminal block 300 may be placed on the carrier 2. At this time, the coupling member 120 is used to engage with the terminal block body 310, and at the same time, a portion of the coupling member 120 is received in the receiving space 316 through the front opening 318, and the sensor body 110 and the connection terminals 320 are spaced apart. In this embodiment, because the connection terminals 320 and the terminal block body 310 are integrally molded, it is difficult to place the sensor 100 and the front cover 200 in the receiving space 316 from behind the terminal block body 310. Therefore, the engagement relationship between the front cover locking portion 124 and the sensor locking portion 220 ensures that the sensor 100, the front cover 200, and the terminal block 300 are assembled and coupled to each other in the correct direction, thereby improving assembly efficiency and product yield.

[0035] It is worth noting that when the terminal block 300 is placed on the carrier 2, a portion of the connection portion 330 is positioned within the auxiliary assembly groove 28. Furthermore, the limiting portion 360 is fitted into the limiting feature 24 of the carrier 2, which further limits the position of the terminal block 300. After that, the sensor 100, the front cover 200, and the terminal block 300 are tightly coupled together through the pressing process of the press die 3, allowing subsequent operations to proceed smoothly.

[0036] During a conventional assembly process that does not use a carrier 2, when placing the sensor 100 and front cover 200 on the terminal block 300, the terminal block 300 must be placed with its front end facing up on the assembly surface, and then the sensor 100 and front cover 200 must be placed or fitted onto it to overcome the effects of gravity. This not only makes it difficult to secure the components, but also requires the terminal block 300 to be turned over when installing another control unit, thereby increasing the number of workstations required for the automated assembly process. In contrast, the ultrasonic sensor assembly method of this embodiment allows the sensor 100, front cover 200, and terminal block 300 to be coupled to each other within the assembly groove 26 of the carrier 2. This not only allows for accurate alignment, but also eliminates the need to turn the terminal block 300, reducing the number of workstations and improving overall assembly efficiency.

[0037] The present invention has been disclosed in the above description in terms of preferred embodiments. Those skilled in the art should understand that the above embodiments are used only to describe the present invention and do not limit the scope of the present invention. It should be noted that any modifications and substitutions equivalent to the above embodiments should be considered to be within the scope of the present invention. As long as no conceptual contradiction or structural conflict occurs, all technical features of the above embodiments may be combined, substituted, omitted, or modified as appropriate. Therefore, the scope of protection of the present invention is pursuant to the claims. [Explanation of symbols]

[0038] 1 ultrasonic sensor 100 sensors 110 Sensor body 112 Housing 114 Joint 116 Chamber 120 Connecting member 122 Combined Body 124 Front cover locking part 126 Terminal block positioning part 128 Storage groove 200 front cover 210 Front cover body 220 Sensor locking part 300 terminal block 310 Terminal block body 316 Containment Space 318 Front Opening 320 connection terminal 330 Connection 340 Auxiliary connection terminal 360 Restricted Section 2. Career 22 Carrier body 26 Assembly groove 26a Front cover receiving groove 26b Front cover positioning groove 26c Sensor housing groove 28 Auxiliary assembly groove 24 Restricted Features 3 Press molds S100-S400 Step XX cross section

Claims

1. a sensor including a sensor body having a non-circular coupling portion, a circular coupling body having an accommodating groove formed on the inside, and a coupling member having a plurality of front cover locking portions; a front cover including a plurality of sensor locking portions that lock with the plurality of front cover locking portions; a terminal block including a terminal block main body having a front opening and an accommodation space communicating with the front opening and accommodating at least a part of the sensor; and a connection terminal disposed in the accommodation space; The receiving groove is disposed on the coupling body; The plurality of front cover locking portions are arranged at uneven intervals along the circumferential direction of the coupling body, An ultrasonic sensor characterized in that the outer shape of the connecting portion of the sensor body includes two opposing arcs and two parallel straight lines connecting the ends of the two arcs, and the connecting member is expanded so that the connecting portion is fitted into the accommodating groove.

2. 2. The ultrasonic sensor according to claim 1, wherein the connection terminals are molded in advance in the housing space or are molded integrally with the terminal block body.

3. 2. The ultrasonic sensor according to claim 1, wherein the at least one sensor positioning portion included in the terminal block body is engaged with the at least one terminal block positioning portion further included in the sensor.

4. 2. The ultrasonic sensor according to claim 1, wherein the ultrasonic sensor is assembled using a carrier having an assembly groove formed therein, the assembly groove including a front cover accommodating groove corresponding to the size of the front cover, and a sensor accommodating groove corresponding to the size of the sensor and recessed relative to the bottom of the front cover accommodating groove.

5. 2. The ultrasonic sensor of claim 1, wherein the ultrasonic sensor is assembled with a carrier including a limiting feature that interlocks with a limiting portion included in the terminal block body.

6. 2. A method for assembling the ultrasonic sensor according to claim 1, comprising the steps of: providing a carrier, the sensor, the front cover, and the terminal block; placing the front cover in an assembly groove of the carrier; a step of engaging the plurality of front cover engaging portions of the sensor and the plurality of sensor engaging portions of the front cover with each other; a step of accommodating at least a portion of the sensor, which is spaced apart from the connection terminal in the accommodating space, in the accommodating space of the terminal block through the front opening of the terminal block; 1. A method for assembling an ultrasonic sensor, comprising:

7. 7. The method for assembling an ultrasonic sensor according to claim 6, wherein the connection terminals are molded in advance in the accommodating space or are molded integrally with the terminal block body of the terminal block.

8. 7. The method for assembling an ultrasonic sensor according to claim 6, further comprising the step of locking at least one terminal block positioning portion of the sensor and at least one sensor positioning portion of the terminal block to each other.

9. 7. The method of claim 6, further comprising interlocking the restraining features of the carrier and the restraining portions of the terminal block.

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