Sensor Connector Sleeve Segmentation for Compact Axial Attachment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensor housings require a large axial expansion and significant forces to establish a press connection due to the need for a large pressing surface, resulting in increased installation depth and complexity.
Innovation Solution
The sensor design features a plug sleeve divided into a front section that is open in cross-section and a rear section that is closed, with form-fitting and counter-form-fitting geometries that allow for rotational securing, enabling axial attachment with reduced pressing surface and force, and a drawer element configuration for compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a press connection is used to attach the plug sleeve to the housing, then a secure connection is achieved, but a large pressing surface and large forces are required, resulting in large axial expansion and increased installation depth
Solution Approach 1:
The plug sleeve is divided into a front section that is open in cross-section and a rear section that is closed in cross-section. The front section engages with the housing to provide rotational securing, while the rear section provides axial support. This segmentation allows the connection to be achieved without requiring a large pressing surface, thus reducing axial expansion while maintaining connection security.
Solution Approach 2:
The plug sleeve features asymmetric geometry with an open front section and closed rear section. The open front section allows for reduced material and smaller pressing surface, while the closed rear section maintains structural integrity. This asymmetric design enables secure connection with minimized axial expansion.
2Reliability
If a press connection with large pressing surface is used, then secure attachment is achieved, but large forces are required which complicates the attachment process
Solution Approach 1:
By segmenting the plug sleeve into open and closed sections, the attachment process can be simplified. The open front section allows for easier insertion and alignment, while the closed rear section provides stable support. This reduces the complexity of the attachment process compared to requiring uniform large pressing surfaces throughout the entire sleeve.
3Strength
If the plug sleeve is designed with closed cross-section throughout, then structural strength is maintained, but the longitudinal extent and installation depth increase
Solution Approach 1:
The plug sleeve is segmented such that only the rear section is closed in cross-section to provide necessary structural strength, while the front section is open to reduce longitudinal extent. This selective closure maintains strength where needed while minimizing overall size.
Solution Approach 2:
Different sections of the plug sleeve have different structural qualities - the front section is open for compactness, while the rear section is closed for strength. This local differentiation of quality allows the structure to be as strong as needed only where required, reducing unnecessary material and longitudinal extent.
Data Source
Figure 1~3
Figure 4~5
Figure 6~8
AI summary
The sensor has a housing with a plug opening that includes housing space. A connector sleeve (26) is connected to the housing. A circuit board with electronic components is located within the housing interior space, and a sensor element is arranged within the housing interior space. The connector sleeve is divided into a front portion (55) and a rear portion (56). A sleeve form-locking geometry and a sleeve mating form-fitting geometry are formed so that the connector sleeve is secured against rotation. An independent claim is included for a method for manufacturing sensor.