Modular Displacement Sensor with Ceramic Insulation
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Solution Overview
Problem
Existing displacement sensors with metal housings face challenges in downsizing while maintaining effective heat dissipation and optical performance.
Innovation Solution
A modular displacement sensor design featuring a metal housing with a ceramic-insulated light projecting and receiving elements, and holder members bonded to an optical base, allowing for further downsizing and improved thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a resin molded frame is used to assemble optical components in a metal housing, then the sensor can be manufactured, but the size cannot be further reduced and heat dissipation becomes inefficient
Solution Approach 1:
The sensor is divided into modular components: a light projecting unit with holder member, a light receiving unit with holder member, and an optical base. Each component can be independently manufactured and assembled, enabling size reduction while maintaining functional integrity and heat dissipation pathways.
Solution Approach 2:
Holder members made of heat-conductive material serve as intermediary components between the optical components and the metal housing. These holder members efficiently transfer heat from the light projecting element and imaging element to the metal housing, solving the heat dissipation problem while allowing compact design.
2Device complexity
If optical components are directly mounted in a metal housing, then assembly is simple, but electrical insulation and thermal management become problematic
Solution Approach 1:
The housing is segmented into an optical base and a metal housing body, with holder members providing intermediate mounting positions. This segmentation allows electrical insulation between optical components and the metal housing while maintaining simple assembly procedures.
Solution Approach 2:
Holder members act as intermediary components that provide both mechanical support and electrical insulation. They are bonded to the optical base and hold the light projecting element and imaging element, preventing direct contact with the conductive metal housing while enabling straightforward assembly.
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 design enables significant downsizing of the displacement sensor, increases flexibility in installation, and maintains effective heat dissipation and optical performance.
Implementation Method 1
the light projecting element and the light receiving element are insulated from the optical base by a ceramic material
Implementation Method 2
the light projecting element and the light receiving element are insulated from the optical base by a ceramic material
Implementation Method 3
a light projecting lens that is fixed to the optical base, condenses the light projected from the light projecting element for forming a light projected spot
Implementation Method 4
a light receiving lens that is fixed to the optical base and condenses light from the detection region to form an image of the light projected spot in the detection region
Implementation Method 5
an imaging element that captures the image of the light projected spot in the detection region formed by the light receiving lens and generates a light receiving signal in accordance with intensity of received light
Implementation Method 6
a first holder member that holds the light projecting element and is bonded to an optical base serving as a part of the metal housing
Data Source
AI summary
Provided is a displacement sensor having a modular structure that allows further downsizing. A housing of a head is made up of a main housing and a lid member, both of which are precision molded products made of a metal material. A first holder to which a light projector is bonded and a second holder to which a light receiver is bonded are individually positioned on and bonded to the lid member. This work is performed by a mounting device. Optical components such as a light projecting lens are also bonded to the lid member, and the lid member modularized by incorporating such optical components is assembled and welded to the main housing.