Inductive Sensor Housing Press-Fit End Cap for Universal Assembly
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Solution Overview
Problem
The existing manufacturing process for inductive sensors requires multiple plastic end caps for different sensor variants, leading to impracticality and increased costs due to the need for separate caps for each design.
Innovation Solution
A universal plastic end cap with a sleeve-like section and a peripheral annular pressing surface that forms a press fit with a metal sleeve-like housing part, allowing for adjustable positioning without mechanical abutments, enabling the same end cap to be used across various sensor designs with different overhangs or flush configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate plastic end caps are used for each sensor variant, then the magnetic field detection is optimized for specific designs, but the manufacturing complexity and cost increase due to requiring multiple cap types
Solution Approach 1:
The patent applies universality by designing a single plastic end cap with a sleeve-like section that can accommodate multiple sensor variants. The sleeve-like section allows the end cap to be adapted to different sensor designs without requiring separate cap types, thereby reducing manufacturing complexity while maintaining detection optimization through proper magnetic field permeability of the plastic material.
2Ease of manufacture
If a press fit connection is used between the end cap and housing part, then the assembly is simplified and manufacturing cost is reduced, but the positioning precision must be maintained without mechanical abutments
Solution Approach 1:
The patent replaces mechanical abutments with a press fit connection system. The peripheral annular pressing surface on the end cap creates friction-based retention within the housing part, eliminating the need for mechanical stop features. This substitution simplifies the manufacturing process while maintaining adequate positioning precision through the interference fit between the pressing surface and housing interior.
3Adaptability or versatility
If the end cap is designed without projecting steps, then the sensor can be manufactured with a universal end cap for multiple variants, but the end cap must be precisely pushed into the housing part to achieve proper positioning
Solution Approach 1:
The patent utilizes parameter changes in the form of the press fit connection, where the interference fit between the pressing surface and housing creates a self-centering effect during insertion. This allows the end cap to be precisely positioned during assembly without requiring projecting steps or mechanical guides, enabling universal applicability while maintaining ease of installation through the inherent alignment properties of the press fit mechanism.
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 eliminates the need for multiple end caps, reduces manufacturing costs, and allows for easy installation by hand or with automated tools, ensuring precise positioning and sealing while maintaining mechanical robustness and adaptability.
Implementation Method 1
the end cap has a peripheral annular pressing surface that has an excess size with respect to an inner diameter of the housing part along an outer diameter of the sleeve-like section so that a press fit is formed between the sleeve-like housing part and the end cap
Data Source
AI summary
A method of manufacturing a housing and a housing for an inductive sensor having at least one sleeve-like housing part and at least one beaker-like end cap for a sensor element, wherein the beaker-like end cap, wherein the end cap is composed of plastic, wherein the end cap is arranged in the sleeve-like housing part, wherein the end cap has a peripheral annular pressing surface that has an excess size with respect to an inner diameter of the housing part along an outer diameter of the sleeve-like section so that a press fit is formed between the sleeve like housing part and the end cap, and wherein a jacket-like outer surface of the sleeve-like section of the end cap does not have a step that projects beyond the inner diameter of the sleeve-like housing part.