Segmented Aluminum Sensor Housing for Optical Access
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Solution Overview
Problem
Existing optoelectronic sensor arrangement housings are costly to manufacture and assemble, with complex component positioning and sealing issues, especially in modular structures, and lack rigidity.
Innovation Solution
A housing composed of two separate elements that can be assembled like a shell, allowing for easier access and testing of components without obstructing the optical axis, and using the aluminum extrusion process for cost-effective production, with openings punched into the front side for optical screens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a one-piece hollow profile (O-profile) is used, then the housing is simple in structure, but the assembly of optoelectronic components is complex and expensive due to narrow access spaces
Solution Approach 1:
The housing is divided into multiple separate components (front side, bottom side, two side walls) that can be assembled together. This segmentation provides better access spaces for assembling optoelectronic components while maintaining structural integrity through the assembly of these separate parts.
2Ease of manufacture
If subsequent processing (milling, drilling, punching) is used to create openings in the front side, then the housing can be manufactured as a one-piece structure, but the manufacturing cost increases significantly
Solution Approach 1:
The openings in the front side are created during the extrusion process itself, before the housing is assembled. This preliminary action allows the openings to be formed cost-effectively as part of the extrusion process rather than requiring expensive subsequent machining operations.
3Device complexity
If optoelectronic components are pushed into the hollow profile from the open end faces, then the housing structure is simple, but the positioning is complex and requires narrow component tolerances
Solution Approach 1:
By dividing the housing into separate components with designated mounting surfaces, the patent provides dedicated locations for optoelectronic components. This segmentation simplifies positioning by establishing clear reference surfaces and access points, eliminating the need for complex precision pushing operations through narrow spaces.
4Ease of operation
If a U-profile with front pane element is used, then access to components is improved, but additional seals are required over the entire length increasing complexity
Solution Approach 1:
The housing is segmented into separate components (front side, bottom side, side walls) that can be assembled with minimal sealing requirements. This segmentation provides component access while avoiding the need for continuous seals over the entire length, reducing overall complexity.
5Ease of operation
If a completely modular structure with separate components is used, then assembly access is improved, but the number of components increases and sealing requirements increase
Solution Approach 1:
The housing is divided into a moderate number of separate components (front side, bottom side, two side walls) that balance accessibility with manufacturing simplicity. This segmentation provides sufficient access for component assembly without requiring excessive numbers of parts or complex sealing arrangements.
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
This design reduces manufacturing costs, simplifies assembly and testing, maintains high rigidity, and avoids the challenges of different material expansion coefficients, while allowing for easy maintenance and repair.
Implementation Method 1
the housings are often produced as a substantially cylindrical hollow profile, for example using the aluminum extrusion process
Implementation Method 2
Openings in the front side, which are necessary so that the light emitted by the light transmitters arranged in the housing can exit the housing
Data Source
Figure 1~2
Figure 3~5
AI summary
The housing has a light transmitter and/or a light receiver, which are formed as cylindrical hollow section with a front side (11), a base side (12) and two side walls (13, 14). The light transmitter and/or a light receiver consists of two units (20, 30), where the units (20, 30) comprises the side walls (13, 14), respectively. The units (20, 30) are detachably connected with each other by a stop or snap mechanism. Openings (24) are stamped in the front side and are designed as an optical blind.