Overmolded Knock Sensor Electrical Connector for Fuel Injector
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing fuel injector systems require complex and costly manufacturing processes for integrating knock sensors, which are essential for closed-loop control and efficient fuel injection performance, as they need to accurately measure pressure fluctuations and valve movements to optimize injection events.
Innovation Solution
An electrical connector with a plastic moulded body integrating a knock sensor, comprising a piezoelectric member sandwiched between a base and seismic member, is overmoulded in a mounting bush, allowing the fixation screw to compress the sensor, simplifying manufacturing and assembly by eliminating the need for pre-compression and reducing the number of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a knock sensor is integrated into the electrical connector using multiple separate components (washers, holding tube, clip member), then the sensor can detect valve movements and pressure fluctuations, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent integrates the knock sensor components (piezoelectric washer, holding tube, clip member) into a single molded electrical connector housing. This merging of multiple separate components into one integrated structure eliminates complex assembly operations while maintaining the sensor's detection functionality for valve movements and pressure fluctuations
Solution Approach 2:
The electrical connector housing serves multiple functions: it provides electrical connectivity and simultaneously houses the knock sensor components. The molded structure integrates both the electrical connection function and the sensor housing function, reducing the overall number of parts and simplifying manufacturing
2Ease of operation
If multiple separate components are used to assemble the knock sensor, then the sensor can be adjusted and installed, but the number of manufacturing operations and assembly steps increases
Solution Approach 1:
The sensor components are molded as an integrated unit within the electrical connector housing, eliminating multiple assembly steps. The single molded structure replaces what would otherwise require separate assembly operations for the washers, holding tube, and clip member, significantly improving manufacturing efficiency
3Reliability
If a complex sensor assembly with multiple components is used, then the knock sensor can be properly compressed and retained, but the manufacturing cost increases
Solution Approach 1:
The sensor retaining structure is integrated into the molded electrical connector housing as a single piece. This eliminates the need for separate washers, holding tubes, and clip members, reducing part count and manufacturing cost while maintaining reliable sensor compression and retention through the molded features
Solution Approach 2:
The patent changes the physical state and integration level of the sensor components from separate assembled parts to an integrated molded structure. This parameter change in the manufacturing approach reduces complexity and cost while maintaining the necessary compression and retention forces for reliable sensor operation
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 solution provides a cost-effective, integrated, and simplified method for detecting valve movements and pressure fluctuations, enabling precise closed-loop control of fuel injectors, enhancing fuel injection performance and reducing manufacturing complexity.
Implementation Method 1
a knock sensor adapted to deliver data representative of the operation of said fuel injector, said knock sensor comprising a piezoelectric member arranged between a base member and a seismic member
Data Source
AI summary
An electrical connector includes two lateral mounting bush. A knock sensor which delivers data representative of the operation of a fuel injector is integrally overmoulded in one of the mounting bush. The knock sensor includes a piezoelectric member arranged between a base member and a seismic member.