Sensor Member Segmented Resin Molding for Cost Reduction
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Solution Overview
Problem
The existing manufacturing process for sensor members requires separate large molds for each vehicle type, leading to increased manufacturing costs due to the need for customized resin molded members.
Innovation Solution
A sensor member design that includes a primary molded part covering the sensor and wire member, and a secondary molded part molded with the primary part and fixing bracket as insert parts, allowing for the production of sensor members with different specifications using a common primary molded part.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a large mold is produced for each specification of fixing bracket, then the sensor member can be manufactured with different specifications, but the manufacturing cost increases
Solution Approach 1:
The resin molded member is divided into a primary molded part and a secondary molded part. The primary molded part is a common component that can be used across different specifications, while the secondary molded part is customized for each specific fixing bracket type. This segmentation allows the system to maintain versatility while reducing manufacturing costs by reusing the primary molded part.
Solution Approach 2:
The primary molded part serves as a universal component that can be used for multiple different specifications of fixing brackets. By designing the primary molded part with standardized interfaces and dimensions, it can accommodate various secondary molded parts, enabling one component to perform multiple functions across different product variants.
2Adaptability or versatility
If a large mold is produced for each specification, then customized resin molded members can be made, but the device complexity increases
Solution Approach 1:
The mold process is segmented into two stages: first molding the primary molded part, then molding the secondary molded part with the primary part as an insert. This segmentation reduces the complexity of individual molds while maintaining the ability to produce customized products, as each mold stage deals with a simpler, more standardized component.
Solution Approach 2:
The primary molded part is prepared in advance as a standardized component before the final customization step. This preliminary action allows the subsequent molding of the secondary molded part to be simpler and more straightforward, as the primary part serves as a pre-prepared insert that reduces the complexity of the final mold configuration.
Data Source
AI summary
Provided is a sensor member that can be easily manufactured even with different specifications. A sensor member includes a sensor, a wire member connected to the sensor, a fixing bracket, and a resin molded member molded as a single body with the fixing bracket and covering the sensor and a portion of the wire member drawn out from the sensor. The resin molded member includes a primary molded part covering the sensor and the portion of the wire member drawn out from the sensor, and a secondary molded part molded with the primary molded part and the fixing bracket as insert parts.