Brake Sensor Assembly With C-Ring Locking Against Vibration Play
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Solution Overview
Problem
Existing sensor assemblies for brake systems face challenges in providing a secure and vibration-resistant connection for the sensor unit, which can be affected by vibrations and require complex assembly processes, potentially compromising the accuracy of monitoring due to play in the sensor unit's mounting.
Innovation Solution
The use of an elastically deformable C-ring held between axial stops in the sensor assembly's plug-in section and shell wall provides a secure, vibration-resistant positive connection, preventing removal of the sensor unit without visible manipulation and ensuring axial and radial play-free mounting, along with a sealing ring and anti-rotation mechanism to enhance accuracy and protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a positive connection with screws or securing ring is used to fasten the cover on the housing, then the connection is secure, but the assembly process becomes complex and the sensor unit remains accessible for manipulation
Solution Approach 1:
The C-ring is extracted from the traditional accessible fastening location and integrated into the plug-in section structure itself, making it invisible and inaccessible from the outside while maintaining its securing function. This eliminates the need for separate visible fastening elements like screws or securing rings.
Solution Approach 2:
The C-ring acts as an intermediary element that provides the positive connection function without being directly accessible. It mediates between the plug-in section and the housing, providing secure fastening while hiding the fastening mechanism from external access.
2Ease of operation
If the sensor unit is mounted on the cover with accessible positioning, then assembly is easier, but the sensor unit becomes vulnerable to manipulation and vibration affects accuracy
Solution Approach 1:
The sensor unit is nested within the housing structure, positioned in the region where the plug-in section is radially opposite the shell wall. This nesting approach protects the sensor unit from external manipulation while maintaining proper assembly alignment through the C-ring's positioning function.
Solution Approach 2:
The C-ring is pre-installed in the plug-in section before final assembly, creating preliminary anti-action against any potential manipulation or vibration. The elastic deformation capability of the C-ring provides continuous counter-action to protect the sensor unit's positioning.
3Ease of manufacture
If traditional fastening elements are used, then assembly is simpler, but vibrations cause play in the connection affecting sensor accuracy
Solution Approach 1:
The C-ring is designed with elastic deformability, allowing it to dynamically adapt to vibrations and thermal expansions. This dynamic property enables the C-ring to maintain constant contact pressure and eliminate play in the connection, ensuring sensor accuracy while keeping the assembly process simple.
Solution Approach 2:
The material parameters of the C-ring are specifically selected to provide optimal elastic deformation characteristics. The ring's elasticity parameter allows it to absorb vibrations and maintain precise positioning, directly improving measurement precision while maintaining assembly simplicity.
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
The solution ensures accurate monitoring by maintaining the sensor unit's axial and radial alignment, preventing vibrations and dirt ingress, while simplifying assembly and enhancing the sensor's operational reliability and protection.
Implementation Method 1
the positive connection has an elastically deformable C-ring which is arranged coaxially with the plug-in section and is held axially, on the one hand, between a first axial stop of the plug-in section and, on the other hand, a second axial stop of the shell wall
Data Source
AI summary
The disclosure relates to a sensor assembly, having a housing, which has a cylindrical depression with a lateral wall which is closed in the circumferential direction of the depression, and having a cover which is assigned to the depression and bears at least one sensor unit, the cover having a cylindrical insertion portion which is partially inserted axially into the depression so that it is radially opposite the lateral wall at least in some regions, and the insertion portion being held axially in the depression by means of an interlocking connection. According to the disclosure, the interlocking connection has an elastically deformable C-ring, which is arranged coaxially with the insertion portion and is held axially between a first axial stop of the insertion portion on one side and a second axial stop of the lateral wall on the other side.