Motor Vehicle Control Device Tolerance Chain Reduction
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Solution Overview
Problem
Existing control units for motor vehicles face challenges in reducing tolerance chains during sensor positioning, which leads to inaccuracies and complex handling processes due to the accumulation of production tool parameters, shrinkage processes, and subsequent oven processes.
Innovation Solution
A control unit design featuring a support plate with a recess for the component carrier foot, allowing for a modular arrangement that eliminates tolerance chains from the overmolding process, with a pressing geometry that fixes the component carrier without play, and a centering pin for precise X/Y positioning, enabling simplified handling and reduced tolerance in the Z-direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If several component carriers are overmolded to form a single monolith, then the housing body enclosing the electronic control unit is formed, but the tolerance chains in positioning the sensor to the part to be sensed increase due to tool parameters, shrinkage processes, and oven processes
Solution Approach 1:
The invention divides the previously integrated monolith into separate component carriers that are not overmolded together. Each component carrier is produced independently, eliminating the cumulative tolerance chains from overmolding multiple carriers into a single monolith. The support plate receives multiple component carriers in a modular arrangement, allowing each carrier to be manufactured with its own reference point without accumulation of tolerances from subsequent carriers.
2Ease of operation
If the component carrier is positioned using traditional methods, then the sensor can be connected to the electronic control unit, but the handling process becomes complex and time-consuming
Solution Approach 1:
The component carrier is pre-positioned on the support plate during the production process using a standardized interface with defined reference points. The support plate includes a recess with specific dimensional tolerances that accommodate the component carrier foot, and the carrier includes a centering pin that automatically positions the carrier in the X/Y direction. This preliminary positioning eliminates the need for complex subsequent alignment operations.
Solution Approach 2:
The support plate serves as an intermediary element between the component carriers and the system interface. It provides a stable mounting surface with a recess that receives the component carrier foot, and it includes positioning features such as the recess geometry that guides and centers the component carrier. This intermediary structure simplifies the connection process by providing a standardized interface that mediates between the component carrier and the final system assembly.
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 design simplifies the handling and positioning of the component carrier, reduces tolerance chains, and allows for cost-effective connection to the system interface, maintaining precise positioning even with temperature fluctuations.
Implementation Method 1
the pressing geometry or the part resting on the pressing geometry is deformed in such a way that the component carrier foot is fixed without play in the recess
Implementation Method 2
The dimensions of the recess in the X/Y direction in the area of the component carrier and in the area of the component carrier foot correspond to the maximum permissible dimensions of the component carrier and the component carrier foot in the X/Y direction
Data Source
Figure 1~2
AI summary
The invention relates to a control device for a motor vehicle, comprising a support plate (1) for receiving an electronic control circuit and at least one component support (4) made of plastic with a component support leg (5), wherein the support plate (1) is provided with dimension tolerances at least in the Z direction and the component support leg in the X/Y/Z direction. The support plate (1) comprises a partially continuous recess (6) through which the component support (4) can be passed and which is suitable for receiving the component support leg (5), wherein the dimensions of the recess (6) in the region of the component support (4) and the component support leg (5) in the X/Y direction correspond to the maximally admissible dimensions of the component support (4) and the component support leg (5) in the X/Y direction. At least one pressing geometry (7) is arranged in the Z direction at the recess (6) or at the component support leg (5) in such a manner that, following the positive- or force-fit connection of the support plate (1) to a system interface (8), the pressing geometry (7) or the part opposite the pressing geometry (7) is deformed to such an extent that the component support leg (5) is fixed without play in the recess.