Plunger-Cylinder Assembly Leadframe Sensor Integration
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Solution Overview
Problem
The existing piston-cylinder arrangements in motor vehicle clutch systems require complex assembly processes and numerous electrical interfaces due to the use of circuit boards for sensor systems, which are susceptible to environmental influences and occupy significant space.
Innovation Solution
The sensor system is integrated into a plastic housing using a leadframe arrangement, eliminating the need for a separate circuit board and reducing electrical interfaces by directly mounting electronic components on the leadframe, which provides mechanical stability and electrical contacting, and is sealed with a cover or casting compound to protect against vibrations and temperature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a circuit board is used to mount the sensor system, then the sensor system can be electrically connected and functionally operated, but the device complexity increases and the required space increases
Solution Approach 1:
The patent combines the circuit board functions directly into the housing structure by integrating contact elements into the plastic housing. The housing itself becomes part of the electrical connection system, eliminating the need for a separate circuit board and reducing overall device complexity while maintaining reliable electrical connections.
Solution Approach 2:
The plastic housing is designed to serve multiple functions: it provides mechanical protection, structural support, and electrical connection pathways. By integrating contact elements and grounding structures into the housing, the component performs both mechanical and electrical functions simultaneously, reducing the number of separate components needed.
2Reliability
If a circuit board is used to mount the sensor system, then the sensor system can be electrically connected, but the number of electrical interfaces increases
Solution Approach 1:
Multiple electrical connection functions are merged into the integrated housing structure. The contact elements, grounding paths, and signal transmission routes are all incorporated into the single housing component, reducing the number of separate electrical interfaces and connection points required.
3Object-affected harmful factors
If a separate sensor housing is used, then the sensor system is protected from environmental influences, but the required installation space increases
Solution Approach 1:
The sensor housing function is merged with the existing piston-cylinder housing. The same housing that contains the mechanical components also provides environmental protection for the sensor system, eliminating the need for a separate sensor housing and reducing overall installation space.
Solution Approach 2:
The housing is designed to serve dual purposes: mechanical containment of the piston-cylinder assembly and environmental protection of the sensor system. This multi-functional design reduces the total number of components and the space required for installation.
4Reliability
If additional mounting process steps are used to attach the circuit board, then the sensor system can be securely mounted, but the manufacturing time increases
Solution Approach 1:
The mounting function is merged into the injection molding process itself. Contact elements and electrical connection features are integrated directly into the housing structure during manufacturing, eliminating separate mounting steps and reducing assembly time while maintaining secure attachment.
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 simplifies assembly, reduces space requirements, and enhances mechanical stability and environmental protection, resulting in a more integrated and efficient piston-cylinder arrangement with fewer parts and reduced production time.
Implementation Method 1
The linear displacement measuring system comprises a sensor system consisting of an inductive sensor unit with an electrically conductive target
Implementation Method 2
Alternatively, a Hall sensor can be used as the sensor system, which includes a permanent magnet positioned on the piston
Data Source
Figure 1
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AI summary
The invention relates to a plunger-cylinder assembly, in particular for a master cylinder of a clutch actuating system in a motor vehicle, having a plunger which is arranged axially movably in a cylinder which is configured as a housing, and having a sensor system which is arranged on the housing and is operatively connected to a sensor constituent part which is fastened to the plunger. In a plunger-cylinder assembly, in which the assembly is simplified by way of a reduction in the interfaces, the sensor system is positioned on a leadframe assembly which is integrated into the plastic housing.