Magnetic Sensor Cable Bending via Injection Molded Positioning
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Solution Overview
Problem
Existing methods for manufacturing magnetic field sensors with angled cable outlets require separate manual processes or additional work steps, leading to increased costs and reduced efficiency, as they cannot be seamlessly integrated into fully automatic production lines designed for axial cable outlets.
Innovation Solution
The method involves integrating positioning means directly onto the connecting cable and fastening strap during injection molding, allowing for fully automatic bending and locking of the cable at desired angles, reducing material costs and process time, and using a cap for temperature protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate manual processes or additional work steps are used for angled cable outlets, then cable positioning flexibility is improved, but production efficiency and automation level deteriorate
Solution Approach 1:
The positioning means are pre-integrated into the injection mold, allowing the cable angle to be predetermined and automatically formed during the injection molding process. This preliminary preparation eliminates the need for subsequent manual positioning operations, thereby maintaining cable positioning flexibility while significantly improving production efficiency and enabling full automation.
2Adaptability or versatility
If separate manual processes or additional work steps are used for angled cable outlets, then cable outlet geometry adaptability is improved, but manufacturing complexity and cost deteriorate
Solution Approach 1:
The injection mold is designed with multi-functional positioning means that can accommodate different cable outlet geometries (angled, radial, axial) through a single unified structure. The positioning means are integrated directly into the mold, allowing the same manufacturing system to produce various cable configurations without requiring separate manual processes or additional work steps, thereby reducing manufacturing complexity while maintaining geometry adaptability.
3Productivity
If positioning means are molded directly onto the connecting cable and fastening strap, then production time and material cost are reduced, but positioning precision requirements increase
Solution Approach 1:
The positioning means are pre-formed as integral parts of the connecting cable and fastening strap during the injection molding process. This preliminary integration ensures that the positioning features are created with high precision controlled by the mold geometry, eliminating the need for subsequent assembly operations. The mold itself acts as the positioning reference, guaranteeing consistent and accurate cable angles while reducing production time and material cost.
4Productivity
If a single production line is used for both axial and angled cable outlets, then production efficiency is improved, but process complexity increases
Solution Approach 1:
The injection mold is designed as a universal tool that can produce both axial and angled cable outlets by incorporating positioning means for different cable configurations. The same production line and injection molding machine can manufacture sensors with various cable geometries by simply changing the positioning means or mold configuration, eliminating the need for separate production lines. This multi-functionality improves production efficiency while the integration of positioning features into the mold keeps the overall process complexity manageable.
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 approach enables efficient, fully automated production of magnetic field sensors with angled cable outlets, reducing production costs and time, while ensuring precise positioning and enhanced durability through reduced sliding friction and torsional stress in the riveted joint.
Implementation Method 1
the positioning means for the connecting cable are at least partially molded directly onto the connecting cable and/or onto the electrical assembly of the sensor and/or onto its fastening strap
Implementation Method 2
The latching and/or riveting contour can be molded onto the connecting cable and, after the cable has been bent into its predetermined angular position, latched or riveted to a positioning means also designed as a latching and/or riveting contour on the fastening tab
Implementation Method 3
In order to bend the cable into the predetermined angular position, the cable no longer has to be removed from the workpiece carrier, since the type of connection enables it to be locked immediately
Data Source
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Figure 5
AI summary
The invention relates to a method for producing a magnetic field sensor (10) and to a sensor produced according to the proposed method, in particular for use as a rotational speed and/or rotational direction sensor for the wheel rotation or the drive train of a motor vehicle. Together with a connection cable (16), the electric subassembly (12) of the sensor (10) is enclosed with plastic by injection moulding and, simultaneously, a fastening lug (14) is sprayed thereon, wherein, after the injection moulding process, the connection cable (16) is bent into an angular position relative to the sprayed subassembly (12) and is positioned and held in this position in the course of the same production process.