Park Lock Actuator PCB Clamping in a Low-Profile Housing
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Solution Overview
Problem
Park lock actuators face challenges in meeting customer packaging constraints while securely retaining a printed circuit board (PCB) in a compact vehicle driveline actuator housing.
Innovation Solution
A housing design with first and second portions that exert a clamping force on the PCB using melted weld material and locating features, eliminating the need for fasteners, and ensuring alignment of position sensing elements for operational feedback.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fasteners are used to retain the PCB, then the PCB is securely retained, but the assembly complexity and manufacturing cost increase
Solution Approach 1:
The housing portions are merged with integrated locating features (bosses, standoffs, ribs) that combine structural support and PCB retention functions into a single component, eliminating the need for separate fasteners and reducing assembly complexity
Solution Approach 2:
The housing portions provide self-retention features through integrated locating structures that automatically secure the PCB through molded-in bosses, standoffs, and ribs without requiring external fastening components or complex assembly procedures
2Volume of moving object
If the actuator housing is made compact to meet packaging constraints, then the packaging efficiency improves, but the PCB retention reliability may be compromised
Solution Approach 1:
The housing portions utilize thin-walled plastic construction with integrated locating features (bosses, standoffs, ribs) that provide adequate PCB retention strength within a compact envelope, eliminating the need for thicker walls or additional retention components
Solution Approach 2:
The locating features extend in multiple dimensions (protruding bosses, vertical standoffs, rib structures) to provide robust PCB retention within the constrained housing volume, utilizing three-dimensional space efficiently to maintain retention reliability without increasing overall actuator size
3Reliability
If multiple retention features are added to the housing, then the PCB retention is improved, but the manufacturing cost and assembly time increase
Solution Approach 1:
Multiple retention functions (locating, support, clamping) are merged into single integrated housing features (bosses, standoffs, ribs), reducing the total number of components and assembly steps while maintaining PCB retention security
Solution Approach 2:
The housing portions provide self-aligning and self-retaining features through molded-in locating structures that automatically secure the PCB during assembly without requiring additional fastening operations or complex alignment procedures, thereby improving assembly speed
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 solution provides secure retention of the PCB in X-, Y-, and Z-directions, reduces assembly time and cost, and maintains a compact actuator envelope.
Implementation Method 1
The PCB is retained in the desired location with melted weld material from the locating features that expands outward to the PCB filling any gaps
Data Source
AI summary
An actuator for a vehicle driveline component includes a housing that has first and second housing portions. The housing provides an electrical connector. A motor is configured to move an output shaft between first and second positions, the motor and the output shaft are arranged in the housing. A gear train is arranged in the housing, the gear train couples the motor to the output shaft. A printed circuit board (PCB) is electrically connected to the electrical connector and the motor. The PCB is retained in a desired location by a clamping force that is exerted on the PCB by the first and second housing portions.