Elastic Coupling Element Displacement Sensor Assembly
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Solution Overview
Problem
Existing displacement sensors for motor vehicle components require complex assembly and multiple parts, leading to increased costs and time due to the intricate joint formation between the coupling rod and lever.
Innovation Solution
A displacement sensor utilizing a displaceable coupling rod, a lever, and an elastic coupling element that converts linear movement into rotary movement, eliminating the need for additional parts in joint formation and simplifying assembly by using a one-piece design with a spring-elastic or tapered elastic coupling element.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a joint with multiple individual parts (ball socket and ball head) is used to connect the coupling rod and lever, then the connection is reliable, but the assembly complexity and manufacturing costs increase
Solution Approach 1:
The ball socket and ball head are merged into a single integrated joint structure that is pre-assembled as one component. This eliminates the need to separately assemble multiple parts during installation, reducing assembly complexity while maintaining the reliable connection function through the integrated design
2Reliability
If a joint with multiple individual parts is used to connect the coupling rod and lever, then the connection function is achieved, but the assembly time and costs increase
Solution Approach 1:
The joint components (ball socket and ball head) are combined into a single pre-assembled unit, transforming a multi-step assembly process into a single installation action. This significantly reduces assembly time while ensuring the connection function is properly implemented through the integrated design
3Reliability
If multiple individual parts are used for the joint between coupling rod and lever, then the connection is functional, but the parts costs increase
Solution Approach 1:
Multiple separate parts (ball socket and ball head) are merged into a single integrated joint component. This reduces the total number of parts required, lowering parts costs while maintaining full connection functionality through the combined structure
Solution Approach 2:
The integrated joint structure performs multiple functions (connection, articulation, and positioning) that were previously distributed across multiple separate components. This multi-functionality reduces the overall part count and associated costs while maintaining all necessary connection capabilities
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 solution reduces parts and assembly costs, allows for easier installation, and maintains the necessary deformation for angle measurement with suitable material properties, enabling the sensor to detect displacements in various motor vehicle components without requiring changes to existing interfaces.
Implementation Method 1
an elastic coupling element (105), which elastically connects the displaceable connecting rod (101) to the lever (103) in order to convert the displacement of the connecting rod (101) into the rotation of the lever (103)
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
The invention relates to a displacement sensor (100) for sensing a displacement of a component of a motor vehicle, comprising a displaceable coupling rod (101), which can be coupled to the component of the motor vehicle in order to sense a displacement of the component, a lever (103) for converting a displacement of the displaceable coupling rod (101) into a rotation that represents the displacement of the displaceable coupling rod (101), and an elastic coupling element (105), which elastically connects the displaceable coupling rod (101) to the lever (103) in order to transfer the displacement of the coupling rod (101) into the rotation of the lever (103).