Motor Vehicle Chassis Sensor Sealing Design
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Solution Overview
Problem
Current ride height sensors in motor vehicles face challenges such as moisture ingress due to multiple leakage paths, high cost, and complexity, particularly in the undercarriage environment where they are exposed to harsh conditions.
Innovation Solution
A sensor assembly design featuring a blind cartridge slot with a single opening for the electrical connector, a rotatable shaft with a magnet, and a magnetic sensitive element, such as a Hall effect or magneto resistive element, housed within a sealed cavity to minimize contamination and reduce complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple leakage paths are present in the sensor assembly, then moisture can enter sensitive electronic components, but sealing these paths increases cost and complexity
Solution Approach 1:
The patent removes the cover or potting material that previously sealed electronic components, eliminating the need for separate sealing structures. The terminal header's wall directly covers the opening between the blind cartridge slot and connector socket, integrating the sealing function into the existing structure without adding complexity
Solution Approach 2:
The terminal header serves dual functions: it provides electrical connections and simultaneously seals the opening between the blind cartridge slot and connector socket. By combining these functions into a single component, the patent reduces the number of separate sealing elements needed
2Reliability
If cover or potting material is used to seal electronic components, then moisture protection is improved, but manufacturing cost increases
Solution Approach 1:
The patent eliminates the cover or potting material entirely, removing the associated manufacturing cost. The terminal header's integrated wall design provides sealing without requiring additional materials or assembly steps
Solution Approach 2:
The terminal header is designed to perform multiple functions: electrical connection and moisture sealing. This multi-functionality eliminates the need for separate sealing components, reducing overall manufacturing cost while maintaining protection
3Reliability
If the sensor assembly uses traditional sealing methods, then reliability is improved, but device complexity and mass increase
Solution Approach 1:
The patent removes traditional sealing methods such as covers or potting material, reducing device complexity. The sealing function is achieved through the terminal header's integrated wall design, which requires no additional components
Solution Approach 2:
The terminal header's wall acts as a thin film barrier that seals the opening between the blind cartridge slot and connector socket. This thin-film approach provides effective sealing with minimal added complexity or mass
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 design effectively seals sensitive electronic components from moisture, reduces leakage paths, and enhances reliability while maintaining the ability to accurately measure ride height, thereby improving performance and reducing manufacturing costs.
Implementation Method 1
the magnetic sensitive element is a Hall effect element or a magneto resistive element
Implementation Method 2
the magnetic sensitive element is a Hall effect element or a magneto resistive element
Data Source
AI summary
A vehicle chassis sensor assembly comprising a housing member defining a sensor cartridge slot, a rotatable shaft with a magnet and retained in a sleeve, and a rotatable arm coupled to the shaft. A sensor cartridge is mounted in the slot through the interior of a connector socket and an opening between the slot and the connector socket. A plate on the sensor cartridge covers the opening. The sensor cartridge includes a terminal header and a separate board mounted to the terminal header. The board includes the sensor. Deformable posts on the terminal header and the sensor assembly extend through respective apertures in the board and the terminal header for securing the board and the sensor cartridge to the terminal header and the sensor assembly respectively.