Integrated Resin Sheath for Rotation Sensor Cable Curvature
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional rotation detection sensor manufacturing process is complex and costly due to the need for separate molding of three resin sheath portions, making cost reduction difficult.
Innovation Solution
A rotation detection sensor with an assembly type sensor body and a cable, where a resin sheath portion is molded integrally with the sensor body and curved cable portion, reducing manufacturing steps and ensuring high durability through recesses formed on opposite sides of the curved portion, and using a resin molding die with specific holding portions to form the curved portion accurately without pre-forming it.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three separate molded portions (primary, secondary, tertiary) are used to sheath the sensor body and cable, then the protection and functionality are ensured, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent combines three separate molded portions (primary, secondary, and tertiary) into a single integrated molded portion that sheaths both the sensor body and the curved cable portion. This merging eliminates the need for multiple separate molding operations and assemblies, thereby simplifying the manufacturing process while maintaining comprehensive protection of the sensor components.
Solution Approach 2:
The single molded portion performs multiple functions simultaneously: it protects the sensor body, protects the cable connection portion, and maintains the curved shape of the cable. This multi-functional design replaces the need for three specialized molded portions, reducing manufacturing complexity while ensuring reliable protection.
2Reliability
If three separate molded portions are used, then comprehensive protection is achieved, but manufacturing cost increases
Solution Approach 1:
By merging three separate molding operations into a single injection molding process, the patent significantly reduces manufacturing costs. The single molded portion is produced in one continuous operation, eliminating the need for multiple material injections, mold changes, and assembly steps, thereby making cost reduction readily achievable.
3Productivity
If the resin sheath portion is molded integrally with the sensor body and curved cable portion, then manufacturing steps are reduced, but maintaining proper cable positioning and sheath thickness becomes challenging
Solution Approach 1:
The patent employs preliminary action by providing holding portions that pre-position the cable in the correct location before the resin injection process begins. These holding portions ensure the cable is properly positioned and the curved shape is maintained during molding, allowing the resin to flow uniformly and form a sheath with consistent thickness without requiring complex real-time positioning mechanisms.
Data Source
AI summary
Provided is a rotation detection sensor and a resin molding die for the sensor, with which manufacturing cost can be readily reduced. The sensor includes an assembly type sensor body having a sensor element and a cable electrically connected to the sensor element. A curved portion is formed at a portion of the cable extending from the sensor body. There is provided a resin sheath portion molded to sheath a portion of the sensor body and the curved portion integrally with resin.