Powdered Metal ABS Sensor Bracket Debris Management
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Solution Overview
Problem
Existing ABS sensor brackets for heavy-duty vehicles are susceptible to damage from road debris, allow debris accumulation, and are costly to manufacture, requiring custom designs for different wheel hub and axle configurations.
Innovation Solution
A robust, debris-deflecting ABS sensor bracket formed from powdered metal with a wedge-shaped configuration, featuring a tubular body and angled legs and feet for secure attachment to the axle, providing improved support and weldability while minimizing debris collection areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sheet metal or cast brackets are used, then manufacturing cost is reduced or production is simplified, but the bracket becomes susceptible to damage from road debris and allows debris accumulation
Solution Approach 1:
The bracket design proactively prevents debris-related damage by incorporating deflecting surfaces that redirect road debris away from the sensor and bracket interior before impact occurs. The wedge-shaped configuration and angled surfaces create a protective action that anticipates and counters the harmful effect of debris accumulation and impact.
Solution Approach 2:
The bracket converts the potentially harmful impact of road debris into a beneficial deflecting action. By designing surfaces that actively redirect debris, the bracket uses the debris' own motion and force to protect the sensor, transforming a harmful factor into a protective mechanism.
2Adaptability or versatility
If custom bracket designs are created for different wheel hub and axle configurations, then adaptability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The bracket is designed with universal mounting features and adjustable elements that allow it to accommodate different wheel hub and axle configurations without requiring custom designs. The standardized body with versatile mounting options enables a single bracket design to serve multiple applications, reducing manufacturing complexity while maintaining adaptability.
3Measurement precision
If precise sensor positioning is ensured through rigid bracket construction, then measurement precision is improved, but the bracket becomes more susceptible to debris accumulation in complex structures
Solution Approach 1:
The design extracts and eliminates internal cavities, recesses, and complex geometries from the bracket structure that could trap debris. By采用 a simplified, streamlined form factor with smooth surfaces and minimal recesses, the bracket maintains structural rigidity for precise sensor positioning while removing the spaces where debris could accumulate.
Data Source
AI summary
A bracket for mounting an anti-lock braking system sensor to a vehicle axle adjacent to a tone ring. The bracket includes a tubular body portion with a surface defining an opening for receiving the anti-lock braking system sensor. A pair of legs, each extending from the body portion. A pair of feet, each define an end portion of a respective one of the pair of legs. Each of the pair of feet is adapted for attachment to an exterior surface of the vehicle axle. The body portion, the pair of legs and the pair of feet are integrally formed as one-piece from powdered metal.