Magnetic Sensor Mounting With Metal Locking Element
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Solution Overview
Problem
Existing magnetic field sensor mounting arrangements face issues with mechanical loading, material compatibility, and temperature-induced detachment, particularly in small, difficult-to-access locations, leading to potential sensor damage and inaccurate position detection.
Innovation Solution
A metal sheet locking element that encompasses the sensor, with a threaded opening for a locking screw, supports the screw on both the groove bottom and shoulders, ensuring a secure, temperature-stable fixation using matching metal materials, and optionally integrated as a threaded bush or with adhesive.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a locking screw directly presses the sensor against groove shoulders, then the sensor can be fixed securely, but the sensor housing is mechanically loaded and may bend or detach
Solution Approach 1:
The invention introduces a locking element as an intermediary component between the locking screw and the sensor housing. This locking element, made of metal, absorbs the mechanical loads and forces during tightening, preventing direct transmission of stress to the plastic sensor housing. The locking element acts as a mediator that transfers the clamping force to the groove shoulders while protecting the sensor from damage.
2Strength
If a plastic sensor housing is clamped with a metal groove, then the sensor can be fixed, but the preload force changes with temperature fluctuations causing unintentional detachment
Solution Approach 1:
The invention applies homogeneity by making both the locking element and the groove shoulders metal. This ensures that both components have similar thermal expansion characteristics, eliminating the differential expansion problems that occur when plastic housing is clamped against metal groove shoulders. The homogeneous metal-metal contact maintains stable preload force across temperature variations.
3Ease of operation
If the sensor housing is wider than the slot opening, then the sensor can be easily inserted and rotated, but the screw head size must be adapted to the groove size increasing complexity
Solution Approach 1:
The invention extracts the screw head from the direct interaction with the groove structure. Instead of the screw head needing to fit within or against the groove shoulders, the screw acts on the locking element which in turn acts on the sensor. This decoupling allows for a standardized screw head design independent of the specific groove dimensions, reducing device complexity.
4Reliability
If spring holders are used to fix the sensor, then the sensor can be secured, but the production becomes complex and the holder must be adapted to each groove shape
Solution Approach 1:
The locking element is designed as a universal component that can be used with different groove shapes and sizes. Unlike spring holders that must be custom-adapted to each groove configuration, the locking element maintains its basic structure and function across various applications. This universality simplifies manufacturing while maintaining reliable sensor security.
Data Source
Figure 1a~2b
Figure 3~5
Figure 6~7b
AI summary
The arrangement comprises a groove shoulder with a narrowing groove opening at its open side and a sensor (12) over its smaller side is inserted into a groove (14) through the groove opening. The sensor is provided with a locking screw (18), which is put through a housing (30) of the sensor. A locking element (16) is provided, which is designed as a sheet and is surrounding the sensor in the cross section almost completely and from the groove base.