Actuator Cover Stamped Grid Hinge Electrical Contact
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Solution Overview
Problem
Existing adjusting devices for internal combustion engines require precise positioning of the cover relative to the housing for reliable electrical contact, which is challenging and labor-intensive, especially when modifications are needed, due to the reliance on welding and separate connection processes.
Innovation Solution
The use of a stamped grid with plastic-encapsulated conductor tracks in the cover, serving as hinges for defined opening and closing, ensures reliable electrical contact and simplified assembly by fixing the cover's position relative to the housing, eliminating the need for welding and separate connection processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If welding connections are used to establish electrical contact between the stamped grid and other electrical components, then reliable electrical contact is achieved, but additional manufacturing process steps and complexity are introduced
Solution Approach 1:
The patent merges the electrical connection function into the injection molding process itself. The stamped grid with conductor tracks is integrated directly into the cover during injection molding, eliminating the need for separate welding operations. The plastic material acts as both structural support and electrical insulation, while the conductor tracks provide electrical pathways without requiring additional joining processes.
Solution Approach 2:
The patent replaces the mechanical welding process with an injection molding process. Instead of using heat and pressure to weld metal components together, the electrical connections are established through the plastic injection molding process that forms the cover and integrates the stamped grid. This substitution eliminates the complexity of welding operations while maintaining reliable electrical contact.
2Reliability
If the cover is positioned precisely relative to the housing axis for electrical contact, then reliable contact is achieved, but assembly becomes labor-intensive and difficult to modify
Solution Approach 1:
The stamped grid with conductor tracks integrated into the cover provides self-aligning electrical connections. The design of the conductor tracks and their integration with the housing features guide the cover into the correct position during assembly, eliminating the need for precise manual positioning. The structure itself ensures proper alignment through its geometric features and electrical contact geometry.
Solution Approach 2:
The electrical connections are pre-configured in the stamped grid during manufacturing, before assembly. The conductor tracks are already positioned and shaped to engage with corresponding contacts in the housing, so that during assembly, the cover simply needs to be placed in the correct orientation without requiring complex positioning adjustments or precision alignment procedures.
3Adaptability or versatility
If separate connection processes are used for electrical components, then flexible modifications are possible, but assembly complexity and production costs increase
Solution Approach 1:
The patent combines multiple manufacturing operations into a single injection molding process. The cover, stamped grid, and electrical connections are all produced in one integrated process, eliminating the need for separate connection steps. This merging reduces production complexity and costs while maintaining the ability to modify designs through changes to the molded tooling.
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 solution provides reliable and long-lasting electrical contact with reduced assembly complexity and production costs, while integrating control electronics and sensors within the cover, allowing for easier installation and reduced space requirements.
Implementation Method 1
non-encapsulated sections of the conductor tracks which serve as a hinge for the defined opening and closing of the cover relative to the housing
Implementation Method 2
sections of conductor tracks which are plastic-encapsulated in the cover
Implementation Method 3
The non-contact angle of rotation sensor is preferably a magnetoresistive sensor, which corresponds to a magnet arranged on an output shaft of the actuating device and is used for position feedback
Data Source
AI summary
The adjusting device has a housing (1), a gearing unit is located in the housing. A drive motor is located in the housing and a lid (22) located to close the housing. A stamped grid has conductors (19) located to electrically connect the drive motor and other electrical and electronic components (20). The stamped grid has plastic-sheathed conductor sections in the lid and non-sheathed conductor sections (23) that serve as a hinge for opening and closing of the lid relative to the housing.