Resin-Held Wiring Assembly for Automated Temperature Sensing
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Solution Overview
Problem
The existing temperature sensor systems for electric motors require manual intervention to lead wires out of a mold, making automation difficult and increasing manufacturing costs.
Innovation Solution
A wiring component with a temperature sensor that includes an electric wire, a temperature sensor with a detection unit and lead wires, and connector pins connected to the lead wires, all collectively held by a resin holder. This holder includes a connector housing member and a molded resin member that covers a portion of the connector housing member, facilitating automated manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual work is used to lead wires out of the mold cavity, then the wires can be positioned correctly, but the working time increases and manufacturing cost increases
Solution Approach 1:
The wire guides are pre-formed as integral parts of the mold cavity before the molding process begins. This preliminary preparation eliminates the need for manual wire positioning during production, allowing automated molding while maintaining precise wire placement.
Solution Approach 2:
The mold cavity structure automatically performs the wire positioning function through its built-in guides and positioning features. The system serves itself by incorporating the positioning mechanism into the mold design, eliminating the need for separate manual intervention.
2Manufacturing precision
If manual work is used to lead wires out of the mold cavity, then the wires can be positioned correctly, but the manufacturing cost increases
Solution Approach 1:
The wire guides and positioning structures are pre-formed as integral parts of the mold cavity. This preliminary preparation enables automated molding processes while maintaining precise wire placement, thereby reducing labor costs and overall manufacturing expenses.
Solution Approach 2:
The mold cavity automatically performs wire positioning through its built-in guides, eliminating the need for manual labor. This self-positioning mechanism reduces both labor costs and manufacturing complexity.
3Measurement precision
If the temperature sensor is positioned close to the electric wire for accurate detection, then the detection accuracy improves, but the sensor may be affected by heat from the wire
Solution Approach 1:
A thermally insulating member is positioned between the temperature sensor and the electric wire. This intermediary component allows the sensor to remain close to the wire for accurate temperature detection while blocking direct heat transfer that would otherwise damage or interfere with the 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
The solution enables automated manufacturing of the wiring component with a temperature sensor, reducing manufacturing costs and improving the accuracy of temperature detection by maintaining a constant distance between the electric wires and the temperature sensor.
Implementation Method 1
a molded resin member covering a portion of the connector housing member
Implementation Method 2
A temperature sensor described in Patent Literature 1 includes a heat-sensitive body such as a thermistor for detecting temperature of a measurement target object
Data Source
AI summary
A wiring component with temperature sensor includes an electric wire, a temperature sensor including a detection unit configured to detect temperature of the electric wire and a plurality of lead wires, and a plurality of connector pins respectively connected to the plurality of lead wires. The electric wire, the temperature sensor and the plurality of connector pins are collectively held by a holder made of a resin. The holder includes a connector housing member configured to hold the plurality of connector pins and a molded resin member covering a portion of the connector housing member.