Photosensor Cable Support for Vibration Resistance
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Solution Overview
Problem
Photosensors connected by pressure-welding in vibrating environments tend to experience cable separation due to short distances between the cable end surface and the pressure-welding point, leading to instability and potential manufacturing process inefficiencies compared to solder connections.
Innovation Solution
A photosensor design with a collective cable support portion, pressure-welding portion, and cable end support portion, where the length from the pressure-welding portion to the cable end support portion is longer than from the collective cable support portion to the pressure-welding portion, absorbing vibrations and reducing separation risks, while maintaining conduction through pressure-welding and incorporating additional support structures to stabilize cable arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the cable is connected to the circuit portion by pressure-welding to reduce manufacturing processes, then manufacturing efficiency is improved, but the cable becomes easily separated in vibrating environments
Solution Approach 1:
The cable support structure is segmented into multiple functional portions: collective cable support portion for initial positioning, pressure-welding portion for electrical connection, and cable end support portion for terminal fixation. This segmentation allows each portion to perform its specific function optimally while working together to prevent cable separation.
Solution Approach 2:
The pressure-welding portion acts as an intermediary between the collective cable support portion and the cable end support portion, providing both electrical conduction and mechanical anchoring. This intermediary structure ensures stable cable connection while maintaining manufacturing efficiency through pressure-welding.
2Volume of moving object
If the distance between the cable end surface and pressure-welding point is short to compact the device, then device size is reduced, but the cable tends to separate under vibration
Solution Approach 1:
The cable support structure utilizes three-dimensional spatial arrangement with the cable extending in multiple directions between support portions. The cable runs from the collective cable support portion, through the pressure-welding portion, to the cable end support portion, creating a distributed spatial configuration that absorbs vibration while maintaining compact overall device dimensions.
Solution Approach 2:
The cable end support portion provides beforehand cushioning by securing the cable end at a distance from the pressure-welding portion. This creates a buffer zone that absorbs vibration and mechanical stress before it reaches the pressure-welding connection point, preventing cable separation while maintaining compact device size.
3Ease of manufacture
If pressure-welding is used instead of solder connection to fix cables, then manufacturing cost is reduced, but connection reliability deteriorates in vibrating environments
Solution Approach 1:
The pressure-welding portion merges multiple functions into a single structure: electrical conduction between the cable and circuit portion, mechanical fixation of the cable, and vibration absorption. This merged structure achieves both manufacturing efficiency through pressure-welding and connection reliability through integrated multi-functional design.
Solution Approach 2:
The cable support structure employs composite construction combining different materials and connection methods: the collective cable support portion for positioning, the pressure-welding portion for electrical and mechanical connection, and the cable end support portion for terminal fixation. This composite approach ensures both ease of manufacture and high connection reliability.
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 design enhances the photosensor's reliability and stability in vibrating environments, reduces manufacturing costs by minimizing processing steps, and allows for a compact, versatile device with improved vibration absorption and reduced electrostatic noise application.
Implementation Method 1
a pressure-welding portion configured to perform conduction with the circuit portion by pressure-welding and fixing each of the plurality of cables
Data Source
AI summary
A photosensor of the present invention includes a circuit portion (34), a collective cable support portion (42), a pressure-welding portion (36a˜36d) and a cable end support portion (46a˜46d). The circuit portion (34) is configured to control the light projecting element and the light receiving element. The collective cable support portion (42) is configured to support a collective cable (10) including a plurality of cables (12a˜12d). The pressure-welding portion (36a˜36d) is configured to perform conduction with the circuit portion (34) by pressure-welding and fixing each of the plurality of cables (12a˜12d). The cable end support portion (46a˜46d) is configured to support an end of each of the plurality of cables (12a˜12d). In each of the plurality of cables (12a˜12d), a length from the pressure-welding portion (36a˜36d) to the cable end support portion (46a˜46d) is longer than that from the collective cable support portion (42) to the pressure-welding portion (36a˜36d).