Open-Profile Chassis Component for Protected Bearing Sensor Mounting
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Solution Overview
Problem
Chassis components, especially those made of sheet metal, often do not allow for the formation of blind-hole-like apertures, making it difficult to attach sensor devices effectively, necessitating an alternative method for integrating sensor housings.
Innovation Solution
A chassis component design featuring a one-piece profile with an open section that houses the sensor device, allowing for protection and close proximity to bearings, using a U-shaped or C-shaped cross-section and a sensor housing fixed via interlocking plug-in portions and fixing means, with the sensor housing made of plastic for enhanced protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a blind-hole-like aperture is formed in the chassis component to attach the sensor device, then the sensor device can be securely attached, but this is not possible with sheet metal chassis components
Solution Approach 1:
The sensor housing is divided into a first section containing the first sensor element and a second section containing the second sensor element, allowing each section to be optimally positioned and attached independently to the chassis component
Solution Approach 2:
A coupling element is introduced as an intermediary component between the sensor housing and the chassis component, enabling attachment without requiring blind-hole apertures in the chassis component itself. The coupling element provides the necessary mounting structure for sensor devices on sheet metal components
2Measurement precision
If the sensor element is positioned close to the bearing for precise measurement, then measurement precision improves, but the sensor element becomes exposed to outside influences
Solution Approach 1:
The first sensor element is nested within the first section of the sensor housing, which is positioned within or adjacent to the bearing structure. This nested arrangement allows the sensor element to be close to the bearing for precise measurement while being protected by the housing structure from outside influences
Solution Approach 2:
The sensor housing acts as a protective shell that encloses the sensor elements, providing physical protection while allowing the housing to be positioned close to the bearing. The housing structure balances protection with measurement proximity
3Reliability
If the sensor housing is fixed onto the chassis component using separate fixing means, then the attachment is secure, but the device complexity increases
Solution Approach 1:
The coupling element integrates multiple functions into a single component: it attaches the sensor housing to the chassis component, provides structural support, and eliminates the need for separate fixing means. This merging reduces assembly complexity while maintaining secure attachment
Solution Approach 2:
The coupling element serves multiple purposes: mechanical attachment, structural support, and positioning of the sensor housing. This multi-functional design simplifies the overall assembly by replacing multiple specialized components with one universal element
Data Source
AI summary
A chassis component (1, 32) has a first end section (2), a second end section (3), and a connecting section (4) between the two end sections (2, 3), with at least one bearing (9, 10) in one of the two end sections (2, 3). A sensor device (13) has a sensor housing (14, 33) with a first sensor element (16). To improve and/or enable the arrangement of the sensor device (13) and/or the sensor housing (14) on the chassis component (1, 32), the two end sections (2, 3) and the connecting section (4) of the chassis are made as a one-piece profile (5) open on one side along its length, such that the open profile (5) forms an at least partially free inside space (17), and where the first sensor element (16) is located within the inside space (17).