Actuator Position Sensor Alignment and Plug Guide Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electric internal combustion engine control arrangements face challenges in achieving precise positioning of position sensors and ensuring reliable electrical connections due to imprecise fastening elements and tolerance deviations, leading to potential misalignment and damage during assembly.
Innovation Solution
A separate positioning arrangement is implemented close to the position sensor, using a positioning pin and hole for precise alignment, and a separate connector tongue guide is used to ensure accurate alignment and reduce mechanical stress on the plug connection components, allowing for improved assembly reliability and durability of electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fastening elements (screws in bores) are used to align the housing cover with the housing body, then assembly is simplified, but positioning accuracy deteriorates because these elements are relatively far away from the position sensor
Solution Approach 1:
The alignment function is segmented into two independent systems: fastening elements for structural attachment and positioning elements (positioning pin and hole) for precise alignment. This separation allows each system to be optimized for its specific function without compromise.
Solution Approach 2:
A dedicated positioning pin and positioning hole are introduced as intermediary elements between the housing cover and housing body. These positioning elements serve as mediators that establish precise geometric relationships independent of the fastening elements, ensuring accurate position sensor alignment.
2Reliability
If the plug tongue is inserted into the insertion slot of the connector clip, then electrical connection is established, but the plug tongue and/or connector clip can bend due to tolerance deviations
Solution Approach 1:
The connector tongue guide is designed to preliminarily guide and align the plug tongue before it engages with the connector clip. This preliminary alignment action prevents misalignment forces that would otherwise cause bending during insertion, ensuring both reliable electrical connection and structural integrity.
3Ease of operation
If the connector tongue is guided and positioned by the connector clip, then alignment is achieved, but the connector clip is subjected to mechanical stress and potential deformation
Solution Approach 1:
The guiding and positioning function is extracted from the connector clip and transferred to a separate connector tongue guide structure. This extraction allows the connector clip to focus solely on providing electrical contact, while the dedicated guide structure handles the mechanical alignment and guiding tasks without subjecting the clip to excessive stress.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to an electrical internal combustion engine actuating arrangement for adjusting actuating elements of an internal combustion engine. The housing body (14) contains a drive motor (12) and is closed off by a housing cover (16). The actuating arrangement has, at the housing cover side, a position sensor (20) which interacts with a position transducer (82) of the housing-body-side drive output shaft (80). The housing cover (16) and the drive motor (14) are electrically connected to one another by means of at least one electrical plug connection arrangement (50, 51). The housing cover (16) and the housing (14) have a positioning arrangement (70) which is composed of a positioning pin (72) and a positioning bore (74). The plug connection arrangement is formed in each case by a plug blade (31, 32) and an opposing plug clamp (34, 35) having a plug-in slot (36, 37). The plug arrangement (50, 51) has, at the plug clamp side, in each case at least one separate plug blade guide (38, 39, 40, 41) with a guide slot (42 to 45) which is arranged in each case parallel to the associated plug-in slot (36, 37) of the respective plug blade (31, 32). It is the object of the invention to create an actuating arrangement whose position sensor is positioned precisely during assembly and which ensures good contact between the drive motor and the housing cover.