Steering Sensor Cover Assembly for Anti-Rotation Wire Harness Coupling
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Solution Overview
Problem
Conventional vehicle steering devices require complex hole and tab machining for coupling the wire harness to the sensor cover, leading to increased component counts and complicated assembly, while also allowing for wire harness rotation.
Innovation Solution
A vehicle steering device design that eliminates the need for hole and tab machining by using a wire harness with a cover portion and a third coupling portion, coupled to the sensor cover and housing via a coupling member, preventing rotation and simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the wire harness is directly screwed to the sensor cover, then the wire harness can be coupled to the sensor cover, but hole and tab machining is required and the number of components increases
Solution Approach 1:
The patent integrates the wire harness coupling function directly into the sensor cover structure by forming a recess on the sensor cover that receives the wire harness. This eliminates the need for separate screw holes and tabs, merging multiple coupling elements into a single integrated structure, thereby reducing component count and assembly complexity while maintaining reliable wire harness attachment
2Reliability
If hole and tab machining is performed for wire harness coupling, then the wire harness can be secured, but processing becomes complicated and assembly is tricky
Solution Approach 1:
The patent segments the wire harness coupling function from the traditional screw-hole-tab approach and integrates it into the sensor cover body itself. The recess structure is formed as an integral part of the sensor cover, eliminating the need for separate machining operations for holes and tabs. This segmentation and integration approach simplifies manufacturing by reducing the number of discrete machining steps required
3Ease of operation
If the wire harness is coupled to the sensor cover, then electrical connection is established, but rotation of the wire harness may occur
Solution Approach 1:
The patent employs an asymmetric recess structure on the sensor cover that is specifically shaped to receive and constrain the wire harness in a fixed orientation. The asymmetric geometry of the recess prevents rotational movement of the wire harness by providing unique engagement surfaces that only accommodate the wire harness in the correct angular position, thereby ensuring positional stability while maintaining ease of connection
Data Source
AI summary
According to the embodiments, a drilling and tapping process for coupling a wire harness to a sensor cover is eliminated, the number of components for coupling the wire harness to the sensor cover is reduced and the assembly process is simplified, and the wire harness coupled to the sensor cover can be secondarily fixed and prevented from rotating.