Vehicle Sensor Cover Mounting for Alignment Without Bending
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Solution Overview
Problem
The existing mounting part structure for external detection sensors in vehicles is prone to bending in the vehicle width direction, which can lead to assembly and manufacturing errors, and does not allow for adequate alignment with the overhead console.
Innovation Solution
A mounting part structure that includes a sensor bracket on the windshield, a console bracket on the ceiling, and a sensor cover with front and rear locking parts that allow for vertical and forward/rearward displacement, while using spring parts to bias the sensor cover in the vehicle width direction, allowing for fine adjustments and preventing bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the rear locking part restricts displacement of the sensor cover in all directions, then the sensor cover is firmly locked to the console bracket, but the sensor cover may bend in the vehicle width direction when it is long
Solution Approach 1:
The locking structure transitions from a completely rigid connection to a dynamic one that permits controlled movement. The rear locking part allows displacement in the vehicle width direction while restricting displacement in vertical and forward/rearward directions, enabling the sensor cover to adjust its shape and position dynamically to prevent bending while maintaining secure locking.
Solution Approach 2:
The invention changes the constraint parameters of the locking mechanism. Instead of restricting all directions of displacement, the rear locking part selectively restricts only vertical and forward/rearward displacement, while permitting width direction displacement. This parameter change allows the sensor cover to accommodate its own length without bending while maintaining reliable locking.
2Manufacturing precision
If the sensor cover is locked firmly in all directions, then assembly errors are absorbed, but the sensor cover cannot be aligned precisely with the overhead console
Solution Approach 1:
The locking mechanism provides dynamic adjustment capability. The rear locking part permits displacement in the vehicle width direction, enabling the sensor cover to be precisely aligned with the overhead console. Simultaneously, the front locking part and adhesion maintain stability in other directions to absorb assembly errors.
Solution Approach 2:
The locking function is segmented between front and rear locking parts with different constraint characteristics. The front locking part restricts vertical displacement and allows width direction displacement, while the rear locking part restricts vertical and forward/rearward displacement but allows width direction displacement. This segmentation enables simultaneous achievement of error absorption and precise alignment.
3Ease of operation
If the sensor cover allows displacement in the vehicle width direction, then alignment with the overhead console is improved, but the stability of the mounting structure is reduced
Solution Approach 1:
The mounting structure achieves a dynamic balance between stability and adjustability. The locking parts permit width direction displacement for easy alignment while restricting displacement in vertical and forward/rearward directions to maintain mounting stability. The adhesion between the sensor bracket and windshield provides additional stabilizing force.
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 configuration enables the absorption of assembly and manufacturing errors, allows for precise alignment with the overhead console, and suppresses backlash, ensuring a stable and accurate installation of the sensor cover.
Implementation Method 1
the rear portion of the sensor cover being biased in the vehicle width direction by a rear spring part
Data Source
AI summary
A mounting part structure of an external detection sensor for a vehicle includes a sensor cover. A front portion of the sensor cover is locked to the sensor bracket via a front locking part that restricts displacement in a vertical direction of the vehicle when displacement of the sensor cover in forward and rearward directions of the vehicle and a vehicle width direction and rotation thereof around an axis following the vehicle width direction are allowed. A rear portion of the sensor cover is locked to the console bracket via a rear locking part that restricts displacement of the sensor cover in the vertical direction of the vehicle and the forward and rearward directions of the vehicle when displacement of the sensor cover in the vehicle width direction is allowed. The rear portion of the sensor cover is biased in the vehicle width direction by a rear spring part.