Damper Assembly Stator Mounting on Dirt Cap
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Solution Overview
Problem
Existing damper assemblies for vehicles are complex and costly, with multiple components that complicate assembly and increase production costs, while also requiring additional parts to maintain cleanliness and protect against environmental stress.
Innovation Solution
A damper assembly design where the stator of the inductive sensor is mounted on a dirt cap that serves as both a support and a protective frame, reducing the number of components and simplifying assembly, with a concentrically positioned dirt cap and a separate cover for the cursor, allowing for easier adjustment and reduced space usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate support structure is used for mounting the stator, then the stator can be securely positioned, but the number of parts increases and assembly complexity increases
Solution Approach 1:
The support structure is merged with the dirt cap by integrating the stator mounting function directly into the dirt cap body. The stator is mounted directly on the outer surface of the dirt cap, eliminating the need for a separate support structure and reducing the total number of parts while maintaining secure positioning.
Solution Approach 2:
The dirt cap is given multiple functions: it continues to protect the damper rod from contamination while also serving as the mounting support for the stator. This multi-functional design reduces the number of separate components needed in the assembly.
2Reliability
If multiple separate components are used for support and protection, then each component can be optimized for its specific function, but production costs increase
Solution Approach 1:
By combining the support function and protection function into a single integrated dirt cap structure, the manufacturing process is simplified. Instead of producing multiple separate components that need to be assembled, a single molded part is produced, reducing production costs and manufacturing complexity.
Solution Approach 2:
The dirt cap is designed to perform multiple functions simultaneously - protecting the damper rod and providing stator mounting - which reduces the total number of parts that need to be manufactured, assembled, and quality-checked, thereby lowering overall production costs.
3Object-affected harmful factors
If additional protective structures are added for the stator, then environmental protection is improved, but the number of parts increases
Solution Approach 1:
The protective function is merged with the mounting function by integrating the stator sealing and fixation directly into the dirt cap structure. The dirt cap body itself provides the protective enclosure while also serving as the mounting support, eliminating the need for separate protective housings or mounting brackets.
Solution Approach 2:
The dirt cap is designed to simultaneously provide environmental protection for the stator and serve as its mounting structure. This multi-functional design protects against mechanical, electrical, and chemical stress while avoiding the need for additional separate protective components.
4Manufacturing precision
If the stator is mounted on a separate support, then positioning accuracy can be achieved, but assembly effort increases
Solution Approach 1:
The positioning accuracy function is merged with the mounting structure by incorporating precise positioning features directly into the dirt cap. The stator is positioned accurately through integrated guide features and mounting surfaces on the dirt cap itself, eliminating the need for separate precision support structures that would require complex assembly procedures.
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 results in a simpler, more cost-effective damper assembly that is easier to assemble, reduces environmental exposure of the stator, and allows for precise positioning of the inductive sensor, enabling efficient determination of vehicle motions and control functions like bank angle and headlight adjustment.
Implementation Method 1
an inductive sensor with a stator and a cursor moveable relative to said stator of said inductive sensor
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a damper assembly, comprising a damper (2) with a tube (2.1) and a piston (2.2) moveable relative to said tube (2.1) of said damper (2) and an inductive sensor (4) with a stator (4.1) and a cursor (4.2) moveable relative to said stator (4.1) of said inductive sensor (4), whereat said stator (4.1) is mounted to a support (6) of said damper assembly stationary to said piston (2.2) and whereat said cursor (4.2) is a part of said tube (2.1). In order to provide another embodiment of a damper assembly, said support (6) is built as a dirt cap (6) for said damper (2) of said damper assembly, whereat said dirt cap (6) comprises an inner surface facing said damper (2) and an outer surface (6.2) not facing said damper (2), and said stator (4.1) is mounted on said outer surface (6.2) of said dirt cap (6).