Acceleration Sensor Welding Assembly Method
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Solution Overview
Problem
Existing acceleration sensors face challenges in assembly due to their small size and weight, requiring complex and time-consuming milling of housing chambers and threaded holes, which limits flexibility and increases production costs, especially for triaxially acting sensors.
Innovation Solution
A method involving pre-installation of sensor elements with piezoelectric measuring elements, seismic mass, and clamping rings, followed by welding to internal supports within the housing, allowing for a simple, flexible, and cost-effective assembly process, enabling precise and planar connections without significant temperature increase or area impairment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If acceleration sensors are made small in size, then they can be used in compact applications, but assembly becomes complex and time-consuming due to milling chambers and threaded holes in the housing
Solution Approach 1:
The sensor element is pre-assembled with the seismic mass and clamping ring outside the housing, and the housing is prepared with receiving structures in advance. This preliminary preparation eliminates the need for complex on-site milling and threading operations, significantly simplifying the final assembly process while maintaining compact sensor dimensions
Solution Approach 2:
The acceleration sensor is divided into separate modular components: the sensor element with base body, the seismic mass, the clamping ring, and the housing with receiving structure. These segments can be manufactured independently and assembled straightforwardly, reducing assembly complexity compared to traditional monolithic designs requiring extensive machining
2Reliability
If traditional assembly methods with milling chambers and threaded holes are used, then secure mounting is achieved, but production time increases and flexibility decreases
Solution Approach 1:
The sensor element is pre-assembled with the seismic mass and clamping ring outside the housing, and the housing is prepared with receiving structures in advance. This preliminary preparation eliminates the need for complex on-site milling and threading operations, significantly simplifying the final assembly process while maintaining compact sensor dimensions
Solution Approach 2:
The clamping ring and seismic mass are combined into a single integrated component. This merging eliminates separate assembly steps for these parts, reduces the number of components to be handled during assembly, and maintains secure mounting without increasing production time
3Adaptability or versatility
If sensor elements are pre-assembled and installed on base, then assembly flexibility improves, but the narrow space in small sensors prevents this approach
Solution Approach 1:
The sensor element is pre-assembled with the seismic mass and clamping ring outside the housing, and the housing is prepared with receiving structures in advance. This preliminary preparation eliminates the need for complex on-site milling and threading operations, significantly simplifying the final assembly process while maintaining compact sensor dimensions
Solution Approach 2:
The assembly process transitions from three-dimensional in-housing assembly to a combination of pre-assembled units placed into the housing. This dimensional change in the assembly approach allows pre-assembly operations to occur in more space, with the completed unit then fitting into the compact final housing
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables quick, precise, and cost-effective installation of acceleration sensors, reducing production time and allowing for modular construction with flexible application, while maintaining sensor sensitivity and reducing assembly complexity.
Implementation Method 1
the head part is encompassed with at least one piezoelectric measuring element
Implementation Method 2
the sensor element is welded in this contact zone with the housing
Data Source
AI summary
The invention relates to a method for producing an acceleration sensor having a housing (1), which has a cylindrical or cubic basic shape, having at least one internal support (4) and having a sensor element (2) arranged thereon. According to the invention a sensor element (2) comprising a main body (29) having a head part (21) and an end face (24) opposing said head part (21) is premounted, by surrounding the head part (21) with at least one piezoelectric measuring element (23), a seismic composition (22) and a clamping ring (27). The end face (24) is subsequently positioned on the inner support (4) of the housing (1) in contact therewith to form a contact zone (7) between the end face (24) and the support (4). Finally, the sensor element (2) is welded in this contact zone (7) to the housing (1). The invention further relates to an acceleration sensor produced using said method.