Sensor Positioning via Injection Molded Shaped Elements
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Solution Overview
Problem
Existing actuating devices for clutches in vehicles, such as electrical central slave cylinders, face inaccuracies in measuring physical parameters due to undesired positional deviations of sensors, leading to incorrect measurement results.
Innovation Solution
The actuating device incorporates a sensor with shaped elements on its outer surfaces for precise positioning, including projections or inserts that connect with complementary elements on the drive device, ensuring exact alignment and fixing the sensor, thereby preventing measurement inaccuracies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the sensor is positioned using abutting against surfaces of the supporting element, then the sensor can be easily installed, but the positioning accuracy is insufficient leading to measurement errors
Solution Approach 1:
The patent replaces the mechanical abutting positioning system with an injection molding positioning system. The shaped elements (protrusions and recesses) are integrated into the sensor housing through injection molding, eliminating the need for separate mechanical positioning components. This allows the sensor to be positioned with high precision while maintaining ease of installation, as the positioning features are formed as integral parts of the housing during manufacturing.
Solution Approach 2:
The positioning features (shaped elements) are pre-formed during the injection molding process of the sensor housing. This preliminary action ensures that the positioning geometry is precisely defined before the sensor is installed on the supporting element, thereby guaranteeing accurate positioning without requiring additional adjustment or complex mechanical positioning mechanisms during installation.
2Measurement precision
If the sensor housing is produced with high precision to ensure accurate positioning, then the measurement accuracy improves, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent replaces complex mechanical positioning systems with an injection molding-based positioning system. The shaped elements are created through the injection molding process itself, which inherently provides high precision without requiring additional machining or assembly steps. This substitution reduces manufacturing complexity while maintaining or improving positioning accuracy.
Solution Approach 2:
The injection molding process serves multiple functions: it creates the sensor housing structure, integrates the shaped positioning elements, and ensures precise dimensional tolerances all in a single manufacturing step. This multi-functionality eliminates the need for separate operations to create positioning features, thereby reducing overall manufacturing complexity while achieving high measurement accuracy.
3Reliability
If the sensor is securely fixed to prevent positional deviations, then measurement reliability improves, but the sensor assembly becomes more complex
Solution Approach 1:
The patent merges the positioning features directly into the sensor housing through injection molding. The shaped elements (protrusions and recesses) are integrated as integral parts of the housing structure, eliminating the need for separate positioning components or additional fastening mechanisms. This merging ensures secure fixation and consistent positioning while keeping the assembly simple.
Solution Approach 2:
The patent replaces complex mechanical fixation systems with an injection molding-integrated positioning system. The shaped elements provide secure mechanical interlocking between the sensor and the supporting element without requiring additional screws, clips, or adjustment mechanisms. This substitution maintains reliability while reducing assembly complexity.
Data Source
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AI summary
The present invention relates to a sensor for detecting at least one physical parameter and to an actuation device. The invention also relates to a method for producing the sensor and to a method for producing the actuation device, and to a friction clutch. The sensor (10) is used to detect at least one physical parameter of a movable element of an actuation device, in particular a central release means for actuating a clutch, or a physical parameter of a movable element of a clutch. The sensor comprises at least one sensitive element (11, 12, 13) for detecting a physical value or state and at least one base element (20) bearing the sensitive element (11, 12, 13), wherein the sensor (10) has, on at least one outer face (51, 52) at least two shape elements (60, 61) for the defined positioning of the sensor (10) on a support. The design of the sensor with the shape elements ensures that the sensor is positioned precisely in relation to elements of the actuation device and consequently can provide precise measurement results.