Impact Sensor Housing Mounting on ECU Casings in Tight Bumpers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing impact sensor assemblies for vehicles face challenges in easy mounting and reliable operation, particularly in limited spaces like the bumper assembly, where dedicated assembly areas are not always available.
Innovation Solution
The impact sensor assembly integrates fixing features on existing larger electronic device casings within the bumper assembly, utilizing mounting elements such as threaded rods, plastic bosses, or flexible brackets to secure the sensor housings, allowing for screwing, heat staking, or snap-on attachment, which simplifies installation and ensures reliable operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the impact sensor assembly is mounted using dedicated assembly areas in the bumper, then the mounting is secure and reliable, but the complexity of the assembly increases and available space is limited
Solution Approach 1:
The electronic device casing serves dual purposes: it houses electronic control units and simultaneously provides mounting surfaces for the impact sensor assembly. The casing integrates fixing features that allow sensor housings to be mounted directly on it, eliminating the need for dedicated assembly areas in the bumper structure.
Solution Approach 2:
The mounting function is merged with the electronic device casing structure. The casing incorporates fixing features such as threaded holes, recesses, or attachment points that directly support the sensor housings, combining the electronic housing and mounting structure into a single integrated component.
2Manufacturing precision
If the impact sensor assembly is mounted using dedicated assembly areas in the bumper, then the mounting position is precise, but the ease of mounting decreases
Solution Approach 1:
The electronic device casing is pre-configured with fixing features during its manufacturing process. Threaded holes, recesses, or attachment points are built into the casing structure before the sensor assembly is installed, allowing for straightforward mounting operations without requiring complex precision alignment procedures.
3Ease of operation
If the sensor housings are mounted on the electronic device casing, then the mounting is simplified and space is utilized efficiently, but the vibration isolation and operational reliability may be compromised
Solution Approach 1:
A mounting element or intermediary component is introduced between the sensor housing and the electronic device casing. This intermediary provides vibration isolation, damping, or decoupling to protect the sensitive pressure sensors from vibrations and mechanical stresses while maintaining a secure mounting connection.
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 configuration facilitates easier and more reliable mounting of impact sensor assemblies on vehicles, particularly in the bumper assembly area, enhancing their ability to detect pedestrian impacts by providing stable and vibration-isolated sensor housings.
Implementation Method 1
A deformable tube connects the first sensor housing and the second sensor housing via its tube connections... the tube extends laterally from a vehicle centreline
Implementation Method 2
Each mounting element is surrounded by a distance element. Preferably, the distance element exhibits damping properties
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The invention relates to an impact sensor assembly (1) for detecting for example the impact of a pedestrian with a vehicle. The impact sensor assembly (1) comprises a first sensor housing (2) and a second sensor housing (3) which are connected via a flexible and deformable tube (7). The first sensor housing (2) is mounted on the surface (22) of one electric device casing (20), and/or the second sensor housing (3) is mounted on the surface (22) of another electric device casing (20).