Modular Button Assembly Reducing Tolerance Accumulation
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Solution Overview
Problem
Conventional controllers with pressure sensors made of soft foam material are prone to increased sensitivity due to accumulated tolerances, making it difficult to distinguish and replace broken button assemblies.
Innovation Solution
A modular button assembly design featuring a pedestal, pressure sensor module, and key cap with pivot assemblies that reduce accumulated tolerances and enhance sensing sensitivity, allowing for easier detection and replacement of the pressure sensor module.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a pressure sensor made of soft foam material is used to enhance sensing sensitivity, then the sensing sensitivity is improved, but the controller becomes easily affected by accumulated tolerances causing values to be overly changed
Solution Approach 1:
The button assembly is divided into separate modular components: a key cap, a pedestal, and a pressure sensor module. This segmentation allows each component to be independently manufactured and assembled, reducing the accumulation of tolerances that would occur in an integrated design. The pressure sensor module can be precisely controlled independently while maintaining high sensing sensitivity.
Solution Approach 2:
The pedestal serves as an intermediary component between the key cap and the pressure sensor module. It includes a pressing portion that transmits force from the key cap to the pressure sensor module, and a supporting portion that provides stable mounting. This intermediary structure helps isolate the sensitive pressure sensor from mechanical tolerances in the upper button components.
2Ease of repair
If the button assembly is broken, then the broken button assembly is hardly distinguished to be caused by the pressure sensor or other structures, but the modular design enables easy detection and replacement of the pressure sensor module
Solution Approach 1:
The button assembly is segmented into distinct replaceable modules, with the pressure sensor module being a separate interchangeable component. This allows technicians to easily identify and replace only the faulty module rather than disassembling the entire button assembly, significantly improving repair efficiency while the modular interfaces maintain manageable complexity.
Solution Approach 2:
The pressure sensor module can be designed with distinct visual characteristics or indicators that help technicians quickly identify it as the sensing component versus other structural parts. This visual differentiation enables rapid diagnosis of whether a malfunction originates from the pressure sensor module or other structures.
3Ease of operation
If the button assembly is pressed, then the button assembly contacts the pressure sensor to complete pressing, but accumulated tolerances cause values to be overly changed
Solution Approach 1:
By segmenting the button assembly into separately manufactured components (key cap, pedestal, pressure sensor module), each component can be precision-manufactured within tighter tolerance bands. The modular assembly process allows for tolerance compensation and adjustment, preventing the accumulation of errors that would occur in a monolithic design.
Solution Approach 2:
The design allows for adjustment of geometric parameters during assembly, such as the height of the pressing portion or the positioning of the pressure sensor module. These parameter adjustments can compensate for manufacturing tolerances and ensure consistent pressing characteristics across all assembled units.
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
The modular button assembly design minimizes accumulated tolerances and improves sensing sensitivity, enabling precise pressure sensing and easy maintenance by transmitting pressing forces effectively through the key cap to the pressure sensor module.
Implementation Method 1
A top of the pressure sensor module has a soft material sensor. The soft material sensor has an elasticity.
Data Source
AI summary
A button assembly includes a pedestal, a pressure sensor module and a key cap. The pedestal has an accommodating groove penetrating upward through a top surface of the pedestal. Two opposite sides of the pedestal protrude oppositely outward to form a lower active portion and a lower pivot portion. The pressure sensor module is mounted in the accommodating groove. The key cap is covered on the pressure sensor module. A bottom surface of the key cap has a contact portion contacting with the pressure sensor module. Two opposite sides of the key cap protrude oppositely outward to form an upper active portion and an upper pivot portion. The upper pivot portion rotate pivoting the lower pivot portion, the upper active portion moves downward and upward with respect to the lower active portion.