Sensor Adapter Locking Geometry to Prevent Wrong Connector Orientation
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Solution Overview
Problem
Existing methods for mounting electronic components on vehicle exterior parts, such as PDC or PTS sensors, often result in incorrect installation due to similar components with different connector orientations, which are only detected during final inspection or at the customer's site, requiring high effort to rectify.
Innovation Solution
A locking device is integrated into an adapter element, ensuring correct installation by allowing components with axially aligned connectors while preventing components with radially aligned connectors, using a design that engages with the incorrect components during assembly, thereby preventing collisions and error detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If components with different connector orientations are made similarly in geometry, then manufacturing cost is reduced and component versatility is improved, but assembly error rate increases
Solution Approach 1:
The patent introduces an adapter element as an intermediary component between the sensor and the vehicle exterior component. The adapter includes a locking device that acts as a mediator to detect and prevent incorrect assembly of sensors with radially oriented connectors. The locking device engages with the housing of correctly oriented sensors while colliding with incorrectly oriented sensors, providing a mechanical verification mechanism that eliminates assembly errors without affecting component versatility.
2Reliability
If a locking device is added to prevent incorrect assembly, then assembly reliability is improved, but device complexity increases
Solution Approach 1:
The adapter element serves multiple functions: it provides mechanical mounting of the sensor, ensures correct orientation through the locking device, and facilitates assembly/removal operations. By combining these functions into a single adapter component rather than adding separate verification mechanisms, the solution improves reliability while minimizing the increase in device complexity.
Solution Approach 2:
The locking device provides self-verifying assembly through its geometric design. The locking protrusion and locking groove automatically engage when the sensor is correctly oriented, and the collision with radially oriented sensors self-evidently prevents incorrect assembly. This self-service mechanism eliminates the need for complex verification systems or additional control mechanisms.
3Reliability
If the locking device is positioned to engage with the housing, then prevention of incorrect assembly is improved, but ease of assembly is reduced
Solution Approach 1:
The locking device uses asymmetric geometry where the locking protrusion is positioned to engage with the housing only when the sensor connector is oriented axially. This asymmetric design creates a clear directional guidance during assembly: correct orientation allows smooth engagement, while incorrect orientation results in collision. The asymmetry provides intuitive assembly guidance without requiring complex mechanisms or reducing ease of operation for correct assembly.
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
Ensures accurate assembly of electronic components by preventing incorrect installation, reducing assembly errors and simplifying the detection of mistakes during the installation process.
Implementation Method 1
the locking device is located in an area that is actually occupied by the 'incorrect' component in its assembly position. Therefore, in the case of an erroneous assembly attempt, a collision occurs between the locking device and the incorrect component, and the assembly error is thus noticed.
Data Source
Figure 1
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AI summary
The invention relates to a method for the error-free assembly of an electronic component (2), in particular a sensor, on a preferably polymeric external attachment (1) of a motor vehicle, wherein the electronic component (2) is provided with a connector (20) for electrical contacting the component (2), the external attachment (1) being equipped with an adapter element (3) for receiving the electronic component (2), and the component (2) being brought into contact with the adapter element (3) and thereby mounted on the external attachment (1). According to the invention, a locking device (4) on the adapter element (3) and/or on the external attachment (1) prevents the accidental assembly of an analogous component (2') with a connector (20') oriented at least substantially radially to the component axis (x').