Gas Sensor Assembly Using Dummy Element to Prevent Film Damage
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Solution Overview
Problem
Existing gas sensor assembly methods face issues with annularly-mounted members displacing during assembly, leading to malfunctions, especially when the sensor element has a protection film, which can be damaged or cause assembly failures.
Innovation Solution
A method and apparatus involving an element dummy with a shape similar to the sensor element, where an annularly-mounted member is fitted to the dummy, and the sensor element is aligned and descended through the dummy's through hole to ensure consistent annular mounting, preventing displacement and protecting the protection film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the sensor element is covered with a protection film on the end portion, then the sensor element is protected from damage, but annularly-mounted members cannot be mounted without causing injuries and exfoliations of the protection film
Solution Approach 1:
The assembly process is divided into two distinct stages: first mounting annularly-mounted members to a dummy element (without protection film), then mounting the actual sensor element (with protection film) separately. This segmentation allows each component to be assembled under optimal conditions without interference from the protection film.
Solution Approach 2:
The dummy element is used as a placeholder in preliminary assembly steps. Annularly-mounted members are mounted to the dummy element before the actual sensor element is installed. This preliminary action enables assembly operations that would be difficult or damaging if performed directly on the protected sensor element.
2Ease of operation
If annularly-mounted members are temporarily mounted to a pin member and then the pin member is pulled out, then the sensor element can be inserted, but the annularly-mounted members are liable to displace
Solution Approach 1:
A dummy element is created as a copy of the actual sensor element, with the same dimensions and shape. This dummy element serves as a stable placeholder during assembly, eliminating the need to pull out pin members and causing annularly-mounted members to remain firmly in position throughout the assembly process.
Data Source
AI summary
A gas sensor assembling method includes a step for placing an element dummy such that it has a longitudinal direction in a vertical direction, wherein the cross-sectional shape of the dummy is similar to the cross-sectional shape of a sensor element, a step for fitting a through hole in an annularly-mounted member to the dummy from above vertically, wherein the through hole included in the annularly-mounted member corresponds to the cross-sectional shape of the sensor element, a step for fitting a tubular member to an outer periphery of the annularly-mounted member from above vertically, an step for placing the sensor element in contact with an upper end portion of the dummy on a single straight line, and an step for descending the dummy downwardly vertically for descending the sensor element and fitting the through hole in the annularly-mounted member to the sensor element.