Sensor Device Circuit Board Press-Fit Lid Assembly
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Solution Overview
Problem
Conventional brake system devices require the simultaneous exchange of pressure sensors and control electronics, leading to high costs and complex manufacturing and assembly processes, especially when multiple pressure sensors are involved, due to mechanical and electrical connections that complicate the separate replacement of these components.
Innovation Solution
The control electronics and circuit board are integrated with the lid as a pre-assembled component, using a press-fit connection to the base housing, with electrically conductive contact springs connecting sensors and actuators directly to the circuit board, allowing for simplified assembly and easy replacement of individual sensors or actuators.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If sensors and control electronics are mechanically and electrically connected in conventional pressure measuring systems, then the device structure is compact, but the exchange of components becomes complex and expensive requiring simultaneous replacement of both sensors and electronics
Solution Approach 1:
The device is divided into separate functional modules: sensors mounted on the base housing and control electronics mounted on the lid. This segmentation allows independent replacement of sensors without affecting the electronics, and vice versa, eliminating the need for simultaneous replacement and reducing maintenance costs.
Solution Approach 2:
Contact springs serve as intermediary elements that provide both mechanical support and electrical connection between the sensors on the base housing and the control electronics on the lid. These contact springs are integrated into the housing structure, simplifying the connection interface and enabling easy component exchange.
2Ease of repair
If control electronics are assigned to individual pressure sensors in separate housings with separate contact surfaces, then component replacement is possible, but the manufacturing and assembly process becomes particularly complex and expensive
Solution Approach 1:
The control electronics are combined with the lid to form a single integrated unit, while sensors are combined with the base housing. This merging reduces the number of separate components and connection interfaces, simplifying both manufacturing and assembly processes while maintaining the ability to replace individual sensor modules.
Solution Approach 2:
The contact springs are pre-integrated into the housing structure during manufacturing, establishing ready-made electrical and mechanical connection paths. This preliminary action eliminates the need for complex connection operations during assembly, improving production efficiency.
3Reliability
If separate contact surfaces are arranged in a punched housing to receive pressure forces, then control electronics are protected from pressure forces, but the arrangement becomes further complicated
Solution Approach 1:
The control electronics are extracted from the base housing and placed on the lid, physically separating them from the high-pressure environment. The lid acts as a protective barrier that isolates the electronics from pressure forces while maintaining electrical connectivity through the contact springs.
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 simplifies production and assembly, reduces costs, and enables the easy exchange of individual sensors or actuators while maintaining electrical connectivity, thereby reducing the burden of complex connections and high replacement costs.
Implementation Method 1
the circuit board is firmly connected to the inside of the lid via press-fit connection agent
Implementation Method 2
the second contact surfaces of the sensors and/or actuators are connected to the first contact surfaces on the circuit board via electrically conductive contact springs
Implementation Method 3
the pressing forces specified by the contact springs on the circuit board are passed through it into the press fit connection and from there into the lid
Data Source
Figure 1~2
AI summary
The invention relates to a device (2) for acquiring and processing sensor measurements and/or for controlling actuators (8), comprising a base housing (4), sensors (6) and/or actuators (8) attached to the base housing (4), a cover (10) which can be connected to the base housing (4) to cover the sensors (6) and/or actuators (8), and a circuit board (12) comprising control electronics (21).For easy mounting of the circuit board and secure contact of the sensors with it, the circuit board (12) is securely connected to the inside of the cover (10) via press-fit fasteners (26), the circuit board (12) has electrically effective first contact surfaces (30) on its side furthest from the cover, the sensors (6) and/or actuators (8) have electrically effective second contact surfaces (34) on their side facing the cover (10), and the second contact surfaces (34) of the sensors (6) and/or actuators (8) are connected to the first contact surfaces (30) via electrically conductive contact springs (28).