Vehicle Seat Belt Switch Assembly Hook Cable Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing vehicle seat belt buckle switch assemblies face challenges in securely positioning and electrically connecting Hall Effect sensors to prevent decoupling under normal stresses and forces, leading to potential errors in signaling the coupling or decoupling of the seat belt.
Innovation Solution
A switch assembly design featuring a Hall Effect sensor located in an inclined relationship within a switch housing with hook-shaped cable ends that wrap around interior posts, providing a secure and direct electrical connection to the sensor terminals, eliminating the need for a separate printed circuit board and enhancing sensor positioning relative to the magnet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wiring methods are used to connect Hall Effect sensor terminals, then the assembly process is simpler, but the connection is not secure and may decouple under normal stresses and forces
Solution Approach 1:
The cable ends are formed with hook-shaped configurations that wrap around and engage with corresponding posts or anchors on the Hall Effect sensor assembly. This curved, interlocking geometry creates a mechanically secure connection that resists decoupling under stress while maintaining structural simplicity.
2Measurement precision
If the Hall Effect sensor is positioned in a standard orientation, then the assembly is easier to manufacture, but the magnetic field sensing accuracy is reduced
Solution Approach 1:
The Hall Effect sensor is positioned at a specific inclined angle relative to the magnet, creating a localized optimal sensing configuration. This inclined positioning optimizes the magnetic field detection accuracy at the sensor location while the overall assembly structure remains compatible with standard manufacturing processes.
3Device complexity
If a separate printed circuit board is used to connect sensor terminals, then the electrical connection is more reliable, but the device complexity increases and space is consumed
Solution Approach 1:
The cable assembly is directly integrated with the Hall Effect sensor terminals through hook-shaped connections, eliminating the need for a separate printed circuit board. This merging of functions maintains electrical connection reliability while reducing overall device complexity and component count.
Solution Approach 2:
The printed circuit board component is extracted and removed from the assembly. Instead, the cable ends are directly configured to connect to sensor terminals, simplifying the structure while maintaining the essential electrical connection function.
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 design ensures secure and reliable operation by preventing decoupling of the Hall Effect sensor terminals, maintaining accurate signaling of seat belt status under various forces and stresses, and optimizing sensor placement for effective magnetic field sensing.
Implementation Method 1
Switch assemblies incorporate magnet/Hall Effect sensor assemblies in which the magnet is located on the seat belt buckle, the Hall Effect sensor is located in the switch housing, and buckling and unbuckling of the seat buckle generates changes in magnetic field which are sensed by the Hall Effect sensor
Data Source
AI summary
A switch assembly for a vehicle seat belt buckle comprising a switch housing defining an interior and a pocket, a cable extending into the interior and including hook-shaped ends extending around posts in the interior of the switch housing. In one embodiment, the interior of the switch housing includes first and second posts positioned in a co-linear and spaced apart relationship and the hook-shaped ends face each other and extend around the first posts and abut against the second posts. In one embodiment, the Hall Effect sensor is positioned in the pocket of the switch housing in an inclined relationship.