Sensor Spacer Module for Vibration Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensor modules for detecting vibrational behavior in mechanical components, such as vehicle wheels, face challenges in achieving a balance between precision, cost, and robustness, often compromising one factor to improve another.
Innovation Solution
A sensor module design featuring a rigidly connected base, spacers, and a circuit board that efficiently transmits mechanical vibrations for wireless signal transmission, with spacers having a body portion and pin portion to effectively couple vibrations from the mechanical component to the circuit board, allowing for precise detection without adverse effects on cost or robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor module uses a complex mounting structure to improve vibration detection precision, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The mounting structure is segmented into distinct functional components: a mounting plate for attachment to the mechanical component, separate spacers for positioning, and a circuit board with integrated sensors. This segmentation allows each component to be optimized independently while simplifying the overall assembly process and reducing manufacturing complexity.
Solution Approach 2:
Spacers are introduced as intermediary elements between the mounting plate and the circuit board. These spacers serve multiple functions: they position the circuit board at a precise distance from the mounting plate, provide mechanical support, and transmit vibrations effectively. This intermediary approach simplifies the mounting structure while maintaining high measurement precision.
2Measurement precision
If the sensor module uses high-precision components to improve vibration detection, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
The spacers are designed to perform multiple functions simultaneously: mechanical positioning, structural support, and vibration transmission. This multi-functionality eliminates the need for separate components for each function, reducing part count and manufacturing cost while maintaining precise vibration detection capabilities.
Solution Approach 2:
The circuit board integrates the vibration sensors directly onto its surface, merging the sensing function with the electronic circuitry. This integration eliminates the need for separate sensor housings and mounting mechanisms, reducing manufacturing complexity and cost while maintaining high measurement precision.
3Reliability
If the sensor module uses a robust mounting structure to improve reliability, then reliability is improved, but device complexity increases
Solution Approach 1:
The mounting structure employs local quality optimization by concentrating robustness where needed: the mounting plate uses thick material and multiple mounting holes for secure attachment, while the spacers provide localized positioning and vibration transmission. This targeted approach ensures reliability without requiring complex structures throughout the entire assembly.
Solution Approach 2:
The sensor module utilizes composite construction combining different materials with complementary properties: the mounting plate and spacers use rigid materials for structural stability and vibration transmission, while the circuit board uses flexible PCB material for electrical connections. This composite approach enhances reliability while keeping the overall structure simple and manageable.
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
The sensor module provides improved vibration detection efficiency while maintaining cost-effectiveness and robustness, ensuring reliable wireless transmission of vibrational data from mechanical components.
Implementation Method 1
The at least one spacer is connected to the base such that the mechanical vibration is transmitted from the base to the at least one spacer, and the circuit board is connected to the base by the at least one spacer such that the mechanical vibration is transmitted from the at least one spacer to the circuit board
Data Source
AI summary
A sensor module configured to detect a vibration of a mechanical component includes a base connectable to the mechanical component, at least one spacer extending from the base, and a circuit board connected to the base by the spacer such that a mechanical vibration is transmitted from the component to the base to the spacer to the circuit board. The circuit board includes a circuit and wirelessly transmits signals indicative of a detected vibration. The spacer includes a body portion and a pin portion projecting from an end of the body portion. The pin portion extends into the at least one hole, and the body portion is blocked from passing though the at least one hole by contact with a region of a first side of the circuit board surrounding the at least one hole.