Gearbox Actuator Sensor PCB Latching for Automated Assembly
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Solution Overview
Problem
The existing actuator units for vehicle gearboxes face complexity in sensor installation, particularly with flexible printed circuit boards, which are difficult to automate and require intricate mounting processes.
Innovation Solution
The actuator unit incorporates a baseplate with preassembled flexible printed circuit boards and sensors, featuring plate-like latching elements with pins for automated mounting, along with a seal for protection and precise positioning, allowing for easier and more efficient sensor installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a flexible printed circuit board is used to mount sensors on actuators, then the sensors can be positioned flexibly along the actuator contour, but the installation becomes complicated and difficult to automate
Solution Approach 1:
The flexible printed circuit board is divided into separate sections, each with its own latching element. This segmentation allows each sensor mounting area to be independently positioned and secured, simplifying the overall installation process while maintaining flexible positioning capabilities along the actuator contour
Solution Approach 2:
Latching elements are pre-attached to the flexible printed circuit board during manufacturing. This preliminary action ensures that the circuit board is ready for automated installation without requiring complex assembly steps during final assembly, resolving the contradiction between flexible positioning and installation simplicity
2Measurement precision
If sensors are mounted directly on actuators, then each sensor can be precisely positioned on its corresponding actuator, but the installation process becomes intricate and time-consuming
Solution Approach 1:
The flexible printed circuit board with multiple sensors and latching elements is treated as a single pre-assembled unit. This merging allows the entire sensor array to be installed as one component rather than individually mounting each sensor, significantly reducing installation time while maintaining precise positioning through the latching mechanism
Solution Approach 2:
Sensors are pre-positioned and secured on the flexible printed circuit board before final installation. This preliminary positioning ensures measurement precision is achieved during manufacturing, allowing rapid automated installation without compromising positioning accuracy
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 simplifies the installation of sensors by enabling automated, precise, and protected mounting, reducing the complexity and effort required for sensor placement while ensuring reliable sealing and accurate positioning.
Implementation Method 1
The latching pins can have elastically deformable lugs which can be pressed into suitable bores or openings in the baseplate and remain there by frictional locking.
Implementation Method 2
A seal is preferably arranged between the actuator and the flexible printed circuit board, and therefore the sensor is readily protected from soiling, in particular from abrasion.
Implementation Method 3
The seal here is advantageously pretensioned, thus resulting in a high sealing effect.
Data Source
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AI summary
The invention relates to an actuator unit for a vehicle gearbox, with a baseplate (10), a plurality of actuators (12) which are mounted on the baseplate (10), a plurality of sensors (20) which are assigned at least to some of the actuators (12), and a flexible printed circuit board (24) on which the sensors (20) are mounted, wherein the flexible printed circuit board (24) is provided with a plurality of latching elements (26) with which it is fixed on the baseplate (10).