Position Sensor Dome Clamping for Vibration Stability
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Solution Overview
Problem
Existing position sensors in internal combustion engines face challenges in securing and positioning the sensor module reliably and cost-effectively, especially under varying temperature conditions and vibrations, as traditional securing methods are costly and prone to instability over time.
Innovation Solution
The use of a carrier module with domes that deform to clamp the sensor module in place, combined with positioning elements and an elastic layer for vibration damping, allows for simple, stable, and cost-effective mounting and positioning of the sensor module, ensuring long-term reliability and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If screwing is used to secure the angle sensor module to the carrier module, then reliability and stability are improved, but manufacturing cost increases
Solution Approach 1:
The patent replaces the mechanical screwing system with a chemical bonding system using adhesive. The adhesive is applied in a recess of the carrier module, and the angle sensor module is pressed onto it with a defined pressing force during curing. This substitution eliminates the need for screws while maintaining secure attachment, thereby reducing manufacturing cost while preserving reliability.
Solution Approach 2:
The patent changes the bonding mechanism from mechanical (screws) to chemical (adhesive). The adhesive's curing process transforms from a liquid state to a solid state, creating a permanent bond. This parameter change in the bonding method allows for cost-effective manufacturing while ensuring stable long-term securing of the sensor module.
2Ease of manufacture
If simpler securing methods are used instead of screwing, then manufacturing cost decreases, but reliability and vibration resistance deteriorate
Solution Approach 1:
The patent employs domed pressing elements with a curved surface that distribute the pressing force evenly across the angle sensor module. This curved geometry ensures uniform adhesive bonding pressure, enhancing the bond strength and vibration resistance without requiring complex mechanical fastening systems, thus maintaining both cost-effectiveness and reliability.
Solution Approach 2:
The adhesive is applied to the carrier module recess before the angle sensor module is mounted. This preliminary action ensures that the bonding surface is prepared in advance, allowing for controlled curing under defined pressing force. This sequence ensures reliable vibration resistance while keeping the manufacturing process simple and cost-effective.
3Manufacturing precision
If the sensor module is secured with high precision positioning, then positioning stability is improved, but device complexity increases
Solution Approach 1:
The adhesive bonding system is self-aligning within the recess of the carrier module. The recess geometry provides natural positioning, and the adhesive flows to fill gaps and ensure uniform bonding. This self-service mechanism achieves high positioning precision without requiring complex external positioning fixtures or adjustment mechanisms, thereby reducing device complexity.
Solution Approach 2:
The recess in the carrier module serves multiple functions: it provides positioning alignment, contains the adhesive, and distributes the pressing force. This multi-functional design achieves precise positioning without adding separate positioning components, thus avoiding increased device complexity while maintaining manufacturing precision.
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 solution provides a stable and precise positioning of the sensor module, reducing the risk of relaxation and thermal expansion issues, while allowing for automatic mounting and reducing manufacturing costs, thus enhancing the reliability and durability of the position sensor under harsh operating conditions.
Implementation Method 1
The respectively free end of the domes is deformed in such a way that the sensor module is clamped in its position... heating up the domes
Implementation Method 2
an elastic layer for vibration damping... damping oscillations and vibrations
Data Source
AI summary
A position sensor, preferably an angle sensor for detecting the rotational angle of a shaft. The position sensor has a lead frame on which the electronic components of the position sensor are arranged and to which they are electrically connected A plastic encapsulation enclosing at least the electronic components, thereby forming a sensor module with the lead frame, and a plurality of electrical connections of the sensor module which are formed by the lead frame and a carrier module accommodating the sensor module. The carrier module has electrical connections connected to the electrical connections of the sensor module in an electrically conducting manner. The carrier module has at least two domes between which the sensor module is arranged. The respective free ends of the domes are deformed in such manner that the sensor module is clamped fixed in its position.