Sensor Unit Screening Panel Tolerance Compensation
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Solution Overview
Problem
Existing sensor units in motor vehicles face challenges in ensuring tolerance compensation in the lateral direction, which affects the accurate placement and functionality of sensor systems like adaptive cruise control devices.
Innovation Solution
A screening panel with a panel frame that surrounds the sensor unit, connected via latching and holding means, and a U-profiled cross-section design with supporting ribs and means, allowing for gap-free integration and tolerance compensation, while also accommodating radiator air flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the sensor unit is fixedly connected to the crossmember, then the sensor mounting position is stable, but tolerance accumulation in the lateral direction cannot be compensated
Solution Approach 1:
The sensor unit is divided into separate components: the sensor holder, sensor panel, and screening panel. These segmented components can be assembled with tolerance compensation, allowing lateral position adjustment while maintaining overall mounting stability.
Solution Approach 2:
The screening panel is designed with adjustable parameters including lateral positioning capability and rotational freedom. This allows the panel to be positioned and oriented to compensate for manufacturing tolerances in the lateral direction while maintaining stable mounting.
2Shape
If the panel frame surrounds the sensor panel completely, then gap-free integration is achieved, but tolerance compensation in the lateral direction is restricted
Solution Approach 1:
The screening panel is designed to be rotatable about the sensor axis, providing dynamic adjustment capability. This rotational freedom allows the panel to adapt to lateral tolerance variations while maintaining gap-free integration with the sensor panel.
Solution Approach 2:
The sensor panel is nested within the screening panel structure, with the sensor holder positioned inside the holding frame. This nested arrangement allows the inner sensor panel to be precisely positioned while the outer screening panel provides tolerance compensation and gap-free integration.
3Strength
If the sensor panel is surrounded by a panel frame, then structural support is improved, but radiator air flow may be obstructed
Solution Approach 1:
The screening panel structure is designed with local openings and a u-profiled cross-section that provides structural support where needed while maintaining open areas for radiator air flow. The supporting ribs provide localized strength without creating complete obstruction.
Solution Approach 2:
The design converts the potential harm of air flow obstruction into benefit by strategically positioning the panel frame and supporting ribs to provide structural support while channeling and directing radiator air flow through designated passages, improving both support and airflow.
Data Source
AI summary
An adaptive cruise control device in a front part of a motor vehicle has a sensor unit fixedly connected to a crossmember of the vehicle body. The sensor unit has a sensor eye. A screening panel assembly is arranged at the front in a manner adjusted to fit a passage opening in the front part of the vehicle. The screening panel assembly has a holding frame mounted behind the passage opening. The holding frame has an opening exposing the sensor eye. An outer panel frame is mounted to the holding frame at the opening of the holding frame to partly surround and expose the sensor eye. An inner sensor panel is between the outer panel frame and the sensor unit and has an opening surrounding and exposing the sensor eye.