Force Sensor Assembly Using Adhesive Sealing Instead of Welding
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Solution Overview
Problem
Existing force sensors face challenges in efficiently measuring and regulating forces, particularly in applications like electromechanical brakes, due to complex assembly processes and high costs associated with traditional welding methods.
Innovation Solution
A force sensor apparatus is designed with a force-compliant element, sensing elements, a printed circuit board, and a sensor housing, utilizing an environmental seal instead of welding to reduce complexity and cost, and includes a method of assembly that involves attaching a PCB to a support ring, coupling sensing elements, and sealing with a sensor cap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding methods are used to assemble force sensor components, then structural strength and reliability are improved, but assembly complexity and manufacturing cost increase
Solution Approach 1:
The patent replaces traditional welding (thermal/mechanical process) with adhesive bonding (chemical process) to join the force-compliant element to the support structure and sensor housing. This substitution eliminates complex welding equipment and procedures while maintaining structural integrity through properly engineered adhesive joints, thereby reducing assembly complexity and manufacturing cost while preserving reliability
2Strength
If traditional welding methods are used to assemble force sensor components, then structural strength is improved, but manufacturing cost increases
Solution Approach 1:
The patent substitutes welding operations with adhesive bonding processes, which eliminate the need for expensive welding equipment, skilled welders, and complex fixture systems. The adhesive bonding process is simpler, faster, and more cost-effective while achieving comparable or superior joint strength through proper surface preparation and adhesive selection
Solution Approach 2:
The patent employs disposable adhesive bonds instead of permanent welding joints, allowing for easier disassembly, repair, and replacement of components. This approach reduces manufacturing costs by enabling simpler production lines and reducing the need for expensive, irreversible joining processes
3Measurement precision
If complex assembly processes are used to ensure measurement accuracy, then measurement precision is improved, but assembly complexity increases
Solution Approach 1:
The patent divides the force sensor into modular components (force-compliant element, support structure, sensor housing, environmental seal) that can be assembled in a simplified sequence. Each component is designed with specific attachment features that guide proper alignment and assembly, ensuring measurement accuracy without requiring complex assembly procedures
Solution Approach 2:
The patent introduces an environmental seal as an intermediary component between the force-compliant element and sensor housing. This seal not only provides environmental protection but also serves as a positioning element that ensures proper alignment and spacing, thereby maintaining measurement precision while simplifying the overall assembly process
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 apparatus achieves accurate force measurement with reduced assembly complexity and cost, enabling efficient integration into various systems such as electromechanical braking systems.
Implementation Method 1
a force-compliant element that deforms in response to forces applied to the force sensor apparatus
Data Source
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AI summary
In a particular embodiment, a force sensor apparatus is disclosed that includes a force-compliant element that deforms in response to forces applied to the force sensor apparatus. The apparatus also includes a sensing element coupled to the force-compliant element and is configured to generate a signal indicating the degree that the force-compliant element deforms in response to the applications of forces to the force sensor apparatus. In this embodiment, the apparatus also includes a printed circuit board configured to receive the signal from the sensing element and a support structure having a surface on which the printed circuit board is coupled. The support structure has an outer rim that is attached to the force-compliant element. The apparatus also includes a sensor housing that covers the printed circuit board. The sensor housing has an outer rim attached to the force-compliant element.