Motor Vehicle Sensor Electrical Component Carrier Mounting
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Solution Overview
Problem
The existing methods for mounting two-wire electrical components in motor vehicle measurement sensors are complex, difficult to reproduce, time-consuming, and expensive, due to the need for precise soldering and bending of wires, which can lead to cracking or breakage under thermal shocks, and often result in incompatible component sizes with the available space around connection pins.
Innovation Solution
A two-wire electrical component carrier is used, which is easy to manufacture and mount, featuring a base with tabs for secure holding and ribs for guiding the carrier into grooves, allowing for effective electrical connection and the creation of flexibility loops to prevent wire damage, while optimizing space usage and simplifying the mounting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two-wire electrical components are mounted directly on connection pins after the electronic measurement module is installed, then electromagnetic compatibility is improved, but the mounting process becomes complex and time-consuming
Solution Approach 1:
The patent applies preliminary action by pre-creating the reception space for the electrical component within the body during the molding process, before the actual component mounting occurs. This allows the component to be easily inserted and positioned without requiring complex post-assembly operations, thereby improving mounting speed while maintaining electromagnetic compatibility
Solution Approach 2:
The patent introduces an intermediary structure - the reception space with guiding ribs and positioning features - that mediates between the body and the electrical component. This intermediary facilitates easy and precise mounting of the component without requiring complex soldering or bending operations, thus improving productivity while ensuring proper electromagnetic shielding
2Reliability
If wires are bent to create flexibility loops to prevent cracking under thermal shocks, then reliability is improved, but the process becomes difficult to reproduce and requires expensive tooling
Solution Approach 1:
The patent applies self-service by designing the reception space with integrated guiding ribs and positioning features that automatically guide the wires into the correct configuration during component insertion. The structure itself provides the flexibility loop formation without requiring external tooling or manual bending operations, making the process easy to reproduce and eliminating the need for expensive specialized tooling while ensuring wire durability under thermal shocks
3Adaptability or versatility
If the electrical component size is reduced to fit available space around connection pins, then adaptability is improved, but the component may become too small to effectively perform its function
Solution Approach 1:
The patent applies dimensionality change by utilizing the third dimension (depth) within the body structure. The reception space is created as a recessed cavity within the body, allowing the electrical component to be positioned in a location that is spatially separated from the connection pins while still maintaining electrical connectivity. This enables the use of larger, more functional components without compromising space compatibility or electromagnetic shielding effectiveness
Data Source
AI summary
A measuring sensor for a motor vehicle, including a body and an electronic measurement module having an integrated circuit for measurement management and a plurality of connection pins that are able to be linked to an electrical communication network of a motor vehicle. The sensor includes an electrical component carrier to which an electrical component is fastened, the component having a first connection wire, connected electrically to a first portion of a first connection pin of the plurality of connection pins of the electronic measurement module and a second connecting wire, connected electrically to a second portion of a second connection pin of the plurality of connection pins of the electronic measurement module.