Sensor Support Body Film Hinge Alignment
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Solution Overview
Problem
Existing sensor device manufacturing methods are inefficient and not well-suited for automated production, with complex assembly processes and limited adaptability to installation spaces.
Innovation Solution
A sensor device design featuring a support body composed of a main body and a receiving body connected via a film hinge, allowing for alignment and improved fixation of the sensor element, with guide channels and fixing elements for precise electrical contacting and overmolding with a plastic housing for protection and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sensor element is attached to a support body and then arranged in a plastic housing, then the sensor device is protected and stabilized, but the assembly process becomes complex and not suitable for automated production
Solution Approach 1:
The support body is divided into a main body and a receiving body that are connected to form an integrated structure. The receiving body is positioned at an angle relative to the main body, creating a unified component that simplifies assembly while maintaining protection and stability functions.
Solution Approach 2:
The receiving body is pre-positioned at a specific angle relative to the main body during manufacturing. This preliminary positioning allows the sensor element to be automatically aligned and secured in the correct orientation when inserted, eliminating complex alignment procedures during final assembly.
2Extent of automation
If the receiving body is positioned at an angle to the main body, then the sensor element can be automatically aligned and secured, but the structural design becomes more complex
Solution Approach 1:
The receiving body is pre-positioned at a specific angle relative to the main body during manufacturing. This preliminary positioning allows the sensor element to be automatically aligned and secured in the correct orientation when inserted, eliminating complex alignment procedures during final assembly.
Solution Approach 2:
The angled receiving body automatically guides and aligns the sensor element during insertion. The geometric configuration of the receiving body relative to the main body creates self-aligning features that automatically position the sensor element correctly without requiring external alignment tools or complex positioning mechanisms.
3Manufacturing precision
If guide channels and fixing elements are added to the main body, then electrical connection precision is improved, but the manufacturing complexity increases
Solution Approach 1:
The guide channels and fixing elements are integrated directly into the main body as part of the molded structure. This merging of features into a single component eliminates the need for separate manufacturing steps to add these elements, reducing overall manufacturing complexity while maintaining high precision for electrical connections.
Solution Approach 2:
The guide channels are designed with specific geometric parameters that precisely control the position and orientation of the cable's electrical conductors. By optimizing these geometric parameters during the molding process, high-precision electrical connections are achieved without requiring complex post-manufacturing adjustments.
4Adaptability or versatility
If the sensor device is designed to be adaptable to various installation spaces, then versatility is improved, but the device complexity increases
Solution Approach 1:
The support body is segmented into a main body and a receiving body that can be positioned at specific angles. This segmentation creates a modular structure that can be adapted to different installation configurations while maintaining a relatively simple overall design. The angled receiving body can be adjusted to accommodate various installation spaces without requiring complex reconfiguration.
Data Source
Figure 1a~1f
Figure 2a~2f
AI summary
Sensor device (1) comprising a sensor element (2) attached to a support body (5), wherein the sensor element (2) has at least one connection contact (4) which is electrically contacted on at least one electrical conductor (14) of a cable (12), wherein the sensor element (2) and the support body (5) are arranged in a housing made of a plastic material, characterized in that the support body (5) is formed by a main body (6) and a receiving body (7) for the sensor element (2) and the main body (6) and the receiving body (7) are connected to each other in a way that allows for alignment.