Segmented Metal Housing for Stroke Sensor Assembly
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Solution Overview
Problem
Existing stroke sensors face challenges in achieving high detection accuracy and ease of assembly, particularly when exposed to large temperature changes or vibrations, as they require metal housings with minimal thermal deformation.
Innovation Solution
A stroke sensor design featuring a housing composed of multiple metal cases with abutting units for easy assembly, a sliding unit to guide the shaft, and a tapered face for alignment, along with a detection unit for the magnetism detection element and an origin returning mechanism to ensure precise positioning and high detection accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a case made of metal material is applied to the housing to reduce thermal deformation and improve detection accuracy, then manufacturing precision is improved, but device complexity increases due to the need for multiple cases with precise assembly structures
Solution Approach 1:
The housing is divided into a first case and a second case that are coupled together. This segmentation allows each case to be manufactured separately with precise metal materials to minimize thermal deformation, while the abutting unit ensures accurate relative positioning between the cases. The segmented structure maintains high detection accuracy without requiring the entire housing to be a single complex piece.
Solution Approach 2:
The abutting unit is designed with a tapered face that guides the positional relationship of the cases before they are screwed together. This preliminary action ensures that the cases are correctly aligned and positioned prior to final assembly, simplifying the overall assembly process while maintaining the precision required for high detection accuracy with metal materials.
2Reliability
If multiple metal cases are used in the housing to minimize thermal deformation, then reliability is improved, but ease of manufacture deteriorates due to increased assembly complexity
Solution Approach 1:
The abutting unit with its tapered face performs the preliminary action of guiding and aligning the first case and second case before they are screwed together. This guidance structure ensures that even though multiple metal cases are used, the assembly process remains straightforward and does not require complex alignment procedures, thus maintaining ease of manufacture while achieving thermal stability.
Solution Approach 2:
The abutting unit acts as an intermediary structure between the first case and second case. It mediates the connection by providing a tapered guiding surface that facilitates easy alignment and coupling of the two metal cases, thereby maintaining ease of manufacture while allowing the use of multiple reliable metal components for thermal stability.
3Manufacturing precision
If an abutting unit with tapered face is added to guide case positioning, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The abutting unit is implemented as a separate, integrated feature within the case structure rather than an additional independent component. By segmenting the guiding function into the tapered face of the abutting unit that is part of the case assembly, the design achieves precise case alignment without significantly increasing overall device complexity. The tapered face is formed as part of the case manufacturing process.
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 provides a stroke sensor that is both easy to assemble and offers high detection accuracy, maintaining axial precision and minimizing eccentricity, while allowing for the use of metal materials that reduce thermal deformation and enhance durability.
Implementation Method 1
a magnetism detection element configured to detect a magnetic force from a magnet varying along with a movement amount of the shaft
Data Source
AI summary
Provided is a stroke sensor that is easy to assemble and has a high detection precision. This stroke sensor is provided with: a housing; a shaft a portion of which is housed in the housing and moves reciprocally around an origin position following a detected object; and a magnetic detection element that detects a magnetic force that is from a magnet and that varies according to the amount of movement of the shaft, wherein the housing comprises a plurality of cases made of a metal material, and is provided with contact parts that guide the positional relationship between the cases before and after the cases are connected by screwing.