Sensor Subassembly Extension Section Adaptation
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Solution Overview
Problem
Existing sensors face challenges in bridging varying distances between coil systems and device plugs or cable connections due to different sensor lengths, leading to increased costs and complexity in assembly, as they require multiple circuit board lengths or flexible connections, which are costly and complex to manufacture.
Innovation Solution
A substructure for sensors featuring a coil system and circuit board with an extension section that can be easily adjusted by separating sections using defined separation points, allowing the substructure to be adapted to different sensor lengths without damaging the circuit board, and incorporating connection elements for cables to maintain consistent cable lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If circuit boards of varying lengths are used to bridge different distances, then the distance between coil system and device plug can be adapted, but the manufacturing cost and inventory complexity increase due to needing multiple circuit board lengths
Solution Approach 1:
The extension section is divided into multiple modular segments that can be selectively removed to achieve different lengths. Each segment can be independently separated from the main circuit board, allowing the same base circuit board to be adapted to various sensor lengths without requiring multiple different board designs.
Solution Approach 2:
The extension section is designed with defined separation points that enable dynamic adjustment of the circuit board length. This allows the same circuit board design to be configured for different sensor lengths by removing appropriate segments, transforming a static component into a dynamically adaptable one.
2Adaptability or versatility
If cable connectors and connector pins of different lengths are used, then different distances can be bridged, but the manufacturing cost and assembly complexity increase
Solution Approach 1:
The extension section integrates multiple functions into a single component: it serves as both the circuit board extension and the mounting structure for cable connectors and indicator LEDs. By combining these elements into one integrated section that can be selectively removed, the system avoids the complexity of separately managing multiple different-length components.
3Length of moving object
If the circuit board is shortened to bridge a smaller distance, then the distance requirement is met, but the circuit board is damaged and requires expensive reprocessing
Solution Approach 1:
The extension section is pre-designed with defined separation points that indicate where cutting should occur. This preliminary preparation allows for clean, precise separation without damaging the main circuit board, as all machining and preparation work has already been done during the initial manufacturing process.
4Adaptability or versatility
If flexible connections are used to bridge distances, then adaptability is achieved, but the assembly becomes very variable and requires manual construction which increases costs
Solution Approach 1:
The extension section is designed as a disposable component that can be easily removed and discarded. Instead of creating complex flexible connections that require manual assembly, the system uses a simple rigid extension section that can be cleanly separated if needed, providing adaptability through a simple, low-cost, automated-friendly process.
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A subassembly (1) for a sensor (50) is described, comprising a coil system (4) and a printed circuit board (2) arranged thereon. An extension section (6) is attached to the printed circuit board (2) such that the printed circuit board (2) is arranged between the coil system (4) and the extension section (6). An interface (22) is provided between the extension section (6) and the printed circuit board (2), the interface (22) enabling easy separation of the extension section (6) from the printed circuit board (2).