Optoelectronic Sensor Mechanical Transmission Tolerance Adjustment
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Solution Overview
Problem
Tolerance fluctuations in mechanical transmission elements of optoelectronic sensors lead to insufficient actuation force, potential damage, and increased manufacturing waste due to mismatched tolerances between the operating surface, electrical button element, and housing components.
Innovation Solution
The method involves arranging and adjusting the mechanical transmission element within the optoelectronic sensor to compensate for component tolerances by moving it into a position that triggers switching and then adjusting its length in the working direction, using techniques such as melting, milling, pinching, or applying adhesive to ensure precise alignment and force distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical transmission element is used to transmit force from the operating surface to the electrical button element, then the switching function can be achieved, but tolerance fluctuations cause insufficient actuation force or potential damage to components
Solution Approach 1:
The patent applies preliminary action by pre-adjusting the mechanical transmission element to compensate for tolerances before final assembly. The transmission element is adjusted to ensure proper force transmission and prevent both insufficient actuation and excessive force that could damage components. This pre-adjustment eliminates the need for post-assembly tolerance compensation and ensures reliable switching function.
Solution Approach 2:
The patent employs parameter changes by adjusting the length of the mechanical transmission element within its adjustment range to compensate for tolerance variations. By changing the dimensional parameter (length) of the transmission element, the system adapts to different tolerance conditions and maintains optimal force transmission, preventing both insufficient actuation and component damage.
2Reliability
If the mechanical transmission element is adjusted to compensate for tolerances, then component damage is prevented, but additional manufacturing steps and complexity are introduced
Solution Approach 1:
The adjustment of the mechanical transmission element is performed as a preliminary action during assembly, before the operating surface is finally mounted. This timing allows the adjustment to be integrated into the manufacturing process without requiring additional complex equipment or procedures, thereby protecting components while minimizing added manufacturing complexity.
Solution Approach 2:
The mechanical transmission element is designed with adjustable length capability, transforming it from a static component to a dynamic one that can adapt to tolerance variations. This adjustability is implemented through a simple mechanism that allows length modification within a specific range, providing tolerance compensation without significantly increasing device complexity.
3Ease of manufacture
If the mechanical transmission element length is fixed during manufacturing, then production is simplified, but tolerance accumulation leads to insufficient actuation stroke
Solution Approach 1:
The mechanical transmission element is pre-adjusted to the correct length during assembly, ensuring proper actuation stroke before final installation. This preliminary adjustment compensates for accumulated tolerances from previous manufacturing steps, achieving precise actuation without requiring extremely tight manufacturing tolerances at each individual step.
Solution Approach 2:
The mechanical transmission element incorporates an adjustable length feature that allows it to adapt to tolerance variations. This dynamic adjustment capability enables the system to maintain precise actuation stroke despite tolerance accumulation during manufacturing, bridging the gap between manufacturing simplicity and manufacturing precision.
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
This approach eliminates the risk of component damage and manufacturing waste by ensuring the optoelectronic sensor operates within the required stroke and force limits, reducing costs and improving reliability.
Implementation Method 1
adjusting its length by melting it
Implementation Method 2
adjusting its length by milling it
Implementation Method 3
adjusting its length by pinching it
Implementation Method 4
adjusting its length by applying adhesive to it
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a method for manufacturing an optoelectronic sensor (10, 30) with an operating element comprising an operating surface (15, 35), an electrical key element (18, 38), and a mechanical transmission element (13, 40) movable as a result of actuation of the operating surface for actuating the electrical key element (18, 38), comprising at least the steps of arranging the electrical key element (18, 38) in or on the optoelectronic sensor (10, 30), inserting the mechanical transmission element (13, 40) into the optoelectronic sensor (10, 30) so that movement of the mechanical transmission element (13, 40) can trigger the switching of the electrical key element (18, 38), moving the mechanical transmission element (13, 40) into a position in which it triggers the switching of the electrical key element (18, 38), and holding the mechanical transmission element in place. transmission element (13,40) in this position, and adjusting the length of the mechanical transmission element (18,38) in the working direction for tolerance elimination and an optoelectronic sensor (10, 30) with an operating element comprising an operating surface (15, 35), an electrical sensing element (18, 38) and a mechanical transmission element (13, 40) movable as a result of actuation of the operating surface (15, 35) for actuating the electrical sensing element, wherein the mechanical transmission element (13, 40) is adapted in the working direction for tolerance elimination and/or is a lever.