Configurable Sensor Housing for Multi-Orientation PCB Connectors
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Solution Overview
Problem
Automotive camera suppliers face increased tooling costs due to the need for separate housing designs to accommodate different connector orientations specified by various automakers, as existing assembly methods require distinct configurations for each orientation.
Innovation Solution
A configurable sensor unit housing with multiple opening positions and a connector device that allows for selectable connector placement, enabling customization during assembly by drilling or plugging holes to align with customer requirements, while using a common housing design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate housing designs are developed for each connector orientation, then customer specifications can be met, but tooling costs increase
Solution Approach 1:
The housing is designed with multiple pre-formed opening positions that can accommodate connectors in different orientations. A single housing design serves multiple functions by supporting various connector orientations through selective use of different opening positions, eliminating the need for separate housing designs for each orientation.
Solution Approach 2:
The housing is segmented into multiple opening positions, each capable of receiving a connector element. This segmentation allows the connector opening to be positioned at different locations and orientations while using the same housing structure, reducing tooling costs while meeting diverse customer specifications.
2Adaptability or versatility
If multiple housing configurations are produced, then different customer requirements can be satisfied, but device complexity increases
Solution Approach 1:
A single universal housing design incorporates multiple opening positions that can serve different connector orientations. This multi-functional approach reduces device complexity by eliminating the need for multiple housing variants while still satisfying diverse customer requirements.
Solution Approach 2:
The housing design allows dynamic configuration of connector positions by selecting which opening positions to use. Rather than creating fixed separate housing designs, the system enables flexible adaptation to different customer requirements through selective assembly practices.
3Ease of manufacture
If a common housing design is used, then tooling costs are reduced, but connector orientation flexibility is limited
Solution Approach 1:
The common housing design is enhanced with multiple pre-formed opening positions, allowing it to serve multiple connector orientation functions. This universal design maintains tooling cost efficiency while providing the flexibility to accommodate various connector orientations through selective assembly.
Solution Approach 2:
Multiple opening positions are pre-formed in the housing during manufacturing, preparing the housing in advance to accommodate different connector orientations. This preliminary action enables flexible assembly configurations without requiring additional tooling or complex modifications.
Data Source
Figure 1~3
Figure 4
AI summary
A sensor unit (10) features a housing (12) configured for selecting the position of an opening (22-24, 29-31) through a side wall that is aligned with a terminal portion of a printed circuit board. A connector device (14) is positionable through the selected opening for electrically communicating between the terminal portion and an external connector.