Hollow Rivet Connection for Position Sensor Assembly
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Solution Overview
Problem
Existing displacement encoder assemblies require inseparable pre-assembly of sensor and transmitter units with methods like gluing, soldering, or welding, which can be material-intensive and prone to over-tightening damage, and do not allow for the use of heat-sensitive components.
Innovation Solution
A hollow riveted connection between the housings of the sensor and transmitter units, guided by a fastening element, facilitates a space-saving, material-efficient assembly that avoids welded or soldered connections, allowing for the use of heat-sensitive components and preventing over-tightening damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welded or soldered connections are used to assemble sensor unit and transmitter unit, then strong and inseparable connection is achieved, but heat-sensitive components are damaged and material usage increases
Solution Approach 1:
The patent replaces thermal joining methods (welding, soldering) with a mechanical hollow riveted connection system. The hollow rivet with integrated fastening element provides a purely mechanical assembly method that avoids heat application, thereby protecting heat-sensitive electronic components while achieving strong, inseparable connection between sensor unit and transmitter unit housings.
2Reliability
If separate fastening elements and overmolded steel bushings are used, then secure mounting is achieved, but material usage and device complexity increase
Solution Approach 1:
The patent merges multiple separate components (fastening element, hollow rivet, and overmolded steel bushings) into a single integrated hollow rivet structure. The hollow rivet contains a cavity that receives and guides the fastening element, eliminating the need for separate bushings and reducing overall component count while maintaining secure mounting functionality.
Solution Approach 2:
The hollow rivet serves multiple functions simultaneously: it acts as a structural connector joining the two housings, provides a guide cavity for the fastening element, and eliminates the need for separate bushings. This multi-functionality reduces device complexity while maintaining mounting security.
3Strength
If traditional assembly methods with multiple components are used, then secure connection is achieved, but assembly time and production cost increase
Solution Approach 1:
The hollow rivet is pre-designed with an integrated cavity structure that guides the fastening element during assembly. This preliminary structural preparation eliminates the need for separate bushings and simplifies the assembly process, allowing for faster installation while maintaining secure connection reliability.
Data Source
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AI summary
The invention relates to a position encoder having a sensor unit (20) and an encoder unit (10) following a motion of a lever by means of a pusher (14), so that the sensor unit (20) captures said motion, wherein the encoder unit (10) and the sensor unit (20) comprise separate housings (12, 22) connected to each other. According to the invention, the connection between the housings (12, 22) of the encoder unit (10) and the sensor unit (20) is implemented by means of a hollow riveted connection (30), wherein at least one fastening element can be guided into the hollow space thereof.