Linear Contact Sensor Assembly for Vibration-Resistant Positioning
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Solution Overview
Problem
Pressure sensors in vehicles face inaccuracies due to misalignment, uneven seating, or added resistance from non-secure electrical connections, leading to unreliable data.
Innovation Solution
A sensor assembly with linear contacts and a support contact is designed to provide a secure compression fit, ensuring level orientation and robust electrical and mechanical connections, preventing data inaccuracies from tolerance variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional electrical connections are used in sensor assemblies, then the device complexity is reduced, but the measurement precision deteriorates due to misalignment and uneven seating
Solution Approach 1:
The electrical connection structure is segmented into multiple linear contacts arranged in a line, where each contact point contributes to the overall electrical connection. This segmentation allows for tolerance compensation across multiple contact points rather than relying on a single critical contact point, thereby improving measurement precision without excessive complexity
Solution Approach 2:
A gasket is introduced as an intermediary component between the sensor assembly and the electrical connection structure. The gasket provides a compliant interface that compensates for misalignment and uneven seating, ensuring reliable electrical connections through the linear contacts while maintaining sensor positioning accuracy
2Reliability
If secure housing with electrical connections is implemented, then the reliability of sensor readings improves, but the sensor movement freedom is reduced
Solution Approach 1:
A gasket with flexible material properties is used to create a secure housing connection while accommodating sensor positioning variations. The flexible gasket maintains reliable electrical connections through its compliance, allowing the sensor to be securely housed without rigid constraints that would prevent necessary positioning adjustments
3Manufacturing precision
If linear contacts with support plane are used, then the manufacturing precision requirements are reduced, but the device complexity increases
Solution Approach 1:
The electrical connection is divided into multiple linear contact points arranged in a line rather than a single point connection. This segmentation distributes the alignment requirements across multiple points, reducing the precision needed for each individual contact while maintaining overall connection reliability
Solution Approach 2:
The linear contact structure serves multiple functions simultaneously: it provides electrical connection, creates a support plane for the sensor assembly, and compensates for manufacturing tolerances. This multi-functionality reduces the need for separate components, offsetting the increased structural complexity with functional integration
Data Source
AI summary
An apparatus including a first linear contact, a second linear contact and a support contact. The first linear contact and the second linear contact may each be connected to corresponding electrical terminals. The support contact may be connected to a housing. The first linear contact and the second linear contact may each provide an electrical connection between corresponding sensor contacts and the corresponding electrical terminals. The first linear contact, the second linear contact and the support contact may be arranged to create a support plane for a sensor package. The first linear contact and the second linear contact may each provide support for the sensor package along a linear peak. The apparatus may enable a secure compression fit of the sensor package within the housing.