Non-Contact Position Sensor With Reversible Mechanical Self-Adjustment
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Solution Overview
Problem
Existing non-contact position sensors for brake pedals are complex and time-consuming to adjust, requiring electrical feedback and being difficult to re-adjust, which complicates assembly and maintenance.
Innovation Solution
A tubular, rotatable assembly apparatus that securely fixes the indicator element to the actuating unit, allowing for self-adjustment without electrical signals and enabling easy re-adjustment by rotating between pre-assembled and final positions, with a force-fit mechanism for secure fixing and release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the indicator element is made adjustable relative to the detector unit using electrical feedback, then the switching accuracy is improved, but the assembly complexity and time consumption increase significantly
Solution Approach 1:
The patent replaces the electrical feedback-based adjustment system with a purely mechanical self-adjustment mechanism. The indicator element is pre-positioned in a defined location relative to the detector unit during manufacturing, eliminating the need for electrical feedback circuits and complex adjustment procedures. This mechanical pre-positioning achieves the required switching accuracy without the complexity of electrical adjustment systems.
Solution Approach 2:
The indicator element is pre-adjusted to its correct position during the manufacturing process rather than during assembly. This preliminary action ensures that the indicator element is already in the optimal position relative to the detector unit before the product reaches the customer, eliminating the need for complex on-site electrical feedback adjustment systems.
2Ease of manufacture
If the detector unit is fixed stationarily on an assembly plate, then the assembly structure is simplified, but the re-adjustment capability is lost
Solution Approach 1:
The patent introduces a rotatable assembly apparatus that can be rotated between a pre-assembled position and a final assembled position. This dynamic mechanism allows the indicator element to be securely fixed in the final position while enabling easy rotation back to the pre-assembled position for re-adjustment if needed, combining structural simplicity with adaptability.
Solution Approach 2:
The assembly apparatus is divided into distinct functional segments: a tubular body for holding the indicator element, a rotatable mounting mechanism for secure fixing, and a pre-assembled position for easy removal. This segmentation allows each part to perform its specific function efficiently while maintaining overall system simplicity and re-adjustment capability.
3Reliability
If a force-fit mechanism is used to secure the indicator element, then the fixing reliability is improved, but the re-adjustment difficulty increases
Solution Approach 1:
The force-fit mechanism is combined with a rotatable mounting apparatus that can be easily rotated between locked and unlocked positions. The force-fit provides reliable securing in the final assembled position, while the rotatable mechanism allows simple rotation back to the pre-assembled position for re-adjustment, maintaining both reliability and ease of repair.
Solution Approach 2:
The indicator element is pre-positioned in a loosely fitted state during manufacturing, allowing easy installation and removal. The force-fit mechanism is then engaged through rotation to provide secure fixing during operation. This preliminary loose fitting followed by secure locking allows both easy re-adjustment when needed and reliable operation during use.
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
Simplifies the assembly process, ensures accurate switching, and allows for reversible adjustment, reducing manufacturing costs and enabling easy reconfiguration as needed.
Implementation Method 1
a sensor for producing a sensor signal in response to a geometrical position of a movable indicator element relative to the sensor
Data Source
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AI summary
A non-contact position sensor (100) with a detector unit (104) has a sensor (110) for producing a sensor signal in response to the geometrical position of a moving indicator element (116) relative to the sensor. In order to allow smooth self-adjustment which is also reversible and permits simple and economical manufacture, the indicator element is mounted on an actuating unit (102) in a final assembled position by an assembly apparatus (118, 120), so that its geometrical position can be changed by the actuating unit. The assembly apparatus is constructed so that in a pre-assembled position it holds the indicator element in a defined position relative to the detector unit while the actuating unit is movable along an actuating axis (144) relative to the indicator element. The assembly apparatus has a substantially tubular form and is rotatable about the actuating axis for movement between the pre-assembled and the final assembled position.