Sensor Assembly Layout for Easier Alignment and EMI Shielding
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Solution Overview
Problem
Manufacturing of sensor assemblies is problematic due to the intricacy of their components, which complicates the assembly process.
Innovation Solution
A sensor assembly design comprising an electrical connector with an annular seat, a media connector, a ground bracket with keys, and a capsule that facilitates easy assembly by using crimped and cold-drawn components for secure connections and shielding against electromagnetic interference (EMI/EMC).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If sensor assemblies use intricate components to achieve precise measurement and shielding, then measurement precision and EMI protection are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent combines multiple functions into the capsule component: it serves as the housing for the sensor element, provides EMI shielding through metallic construction, and acts as a mounting structure for the electrical connector. The electrical connector integrates both electrical connection functionality and mechanical positioning features (annular seat, keys) within a single component. This merging reduces the number of separate parts while maintaining precise measurement capability and EMI protection.
Solution Approach 2:
The capsule is designed as a multi-functional component that simultaneously provides structural housing, electromagnetic shielding, and mechanical support for internal components. The electrical connector serves multiple purposes: establishing electrical connections, providing mechanical alignment through keys and slots, and enabling secure mounting via the crimped portion. This multi-functionality reduces overall device complexity while maintaining measurement precision.
2Measurement precision
If sensor assemblies use intricate components with precise alignment requirements, then measurement precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The electrical connector is pre-formed with integrated positioning features (annular seat, keys, grooves) during its manufacturing process. The capsule is cold-drawn into its final shape with precise dimensional tolerances before assembly. These preliminary actions ensure that when components are assembled, the alignment requirements are already built into the component geometries, simplifying the final assembly process while maintaining measurement precision.
Solution Approach 2:
The patent introduces intermediate positioning features as mediators between components: the annular seat acts as an intermediary between the electrical connector and capsule for axial positioning, while the keys and grooves serve as intermediaries for radial positioning and rotational alignment. These intermediary features translate the complex alignment requirements into simple geometric interfits, making manufacturing and assembly easier while ensuring precise component alignment for measurement accuracy.
3Ease of manufacture
If the capsule is cold drawn to provide a smooth surface for visual identifiers, then ease of manufacture and surface quality are improved, but device complexity increases due to the crimping process
Solution Approach 1:
The capsule manufacturing process utilizes parameter changes through cold drawing, which transforms the material state and shape to achieve the desired smooth cylindrical surface. This single-parameter change (cold drawing) accomplishes multiple goals: creating the smooth surface for visual identifiers, establishing precise dimensional tolerances, and forming the overall capsule geometry. The subsequent crimping operation is a localized parameter change that adds the securing function without significantly increasing overall device complexity.
Data Source
AI summary
A sensor assembly includes an electrical connector with an annular seat, a media connector, at least one PCBA with a PCBA slot, a ground bracket with at least one ground bracket key inserted into the PCBA slot and at least one capsule, wherein an internal capsule annular seat abuts the annular seat. The disclosure further discloses a method for assembling the sensor assembly having the steps of connecting the ground bracket to the media connector; connecting the capsule to the media connector; inserting the PCBA into the capsule; and inserting the electrical connector at least partially into the capsule.