Vehicle Sensor Holder Hook Coupling Assembly
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Solution Overview
Problem
Conventional sensor apparatuses for vehicles require multiple parts and complex assembly processes, leading to increased manufacturing time and cost, as well as potential assembly defects and tolerances due to the use of bolts and nuts.
Innovation Solution
A sensor apparatus comprising a protector, a holder, and a sensor, where the protector is inserted into a deck with hooks and extension ribs that elastically deform to accommodate varying deck thicknesses, eliminating the need for bolts and nuts and simplifying assembly by using hook coupling and tolerance removal ribs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional bolt and nut fastening structure is used to assemble sensor holder to deck, then the sensor apparatus can be securely fixed, but the number of parts and assembling processes increases
Solution Approach 1:
The patent combines multiple fastening functions into a single integrated sensor holder structure. The sensor holder incorporates both the mounting function and the fastening function through its hook structure that directly engages with the deck, eliminating the need for separate bolts, nuts, and sensor holders. This merging of functions reduces the number of parts while maintaining secure fixation.
Solution Approach 2:
The patent extracts and eliminates unnecessary intermediate components from the conventional fastening system. By removing bolts, nuts, and separate sensor holders, the design achieves direct engagement between the sensor mounting structure and the deck through the integrated hook structure, thereby reducing part count and simplifying the assembly process.
2Strength
If conventional bolt and nut fastening structure is used to assemble sensor holder to deck, then the sensor apparatus can be securely fixed, but the assembling time increases
Solution Approach 1:
The sensor holder is pre-formed with the hook structure during manufacturing, so that no additional fastening components need to be assembled during installation. The hook structure is already in its final configuration, ready to engage with the deck, which eliminates the time-consuming steps of assembling bolts, nuts, and sensor holders during the installation process.
Solution Approach 2:
By merging the mounting and fastening functions into a single integrated structure, the patent reduces the number of assembly steps. The sensor holder with integrated hook structure can be installed as a single component, eliminating the sequential assembly operations required for conventional multi-component fastening systems.
3Ease of manufacture
If bolt is welded to deck and nut is screwed to bolt, then the sensor holder can be assembled to deck, but assembly defect or assembly tolerance occurs
Solution Approach 1:
The patent replaces the conventional mechanical fastening system (welding and screwing) with a direct hook engagement system. The hook structure of the sensor holder engages with corresponding features on the deck through a simple insertion and locking mechanism, eliminating the complex multi-step processes of welding bolts and screwing nuts, thereby reducing assembly defects and tolerances.
Solution Approach 2:
The sensor holder's hook structure is designed to self-align and self-lock into the deck during installation. The hook engages with the deck features in a self-guiding manner, eliminating the need for precise pre-positioning and reducing assembly tolerance. The structure essentially assembles itself through its geometric design rather than requiring precision fastening operations.
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 reduces the number of parts and assembly processes, minimizes manufacturing costs, and eliminates assembly defects and tolerances by using a simplified assembly method that adapts to deck thickness variations, ensuring secure and efficient sensor installation.
Implementation Method 1
The protector ring may include one or more tolerance removal ribs, which are elastically deformable. An extent of deformation of the one or more tolerance removal ribs may be at least dependent on a thickness of the deck.
Data Source
AI summary
A sensor apparatus for a vehicle includes a protector, a holder, and a sensor. The protector is inserted into an insertion hole of a deck of the vehicle. The protector includes protector hooks formed thereon. The holder is inserted into the insertion hole and coupled to the protector so as to be constrained by the protector hooks. The holder includes holder hooks formed so as to be hooked to an inner surface of the deck. The sensor is coupled to the holder.