Bumper Sensor Tube Groove Layout for Length Error Assembly
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Solution Overview
Problem
The existing sensor tube arrangement between the bumper beam and shock absorber faces difficulties in assembly due to length errors, making it challenging to embed the sensor tube into the groove of the shock absorber effectively.
Innovation Solution
A sensor arrangement structure featuring a shock absorber with an expansion groove portion of greater width than the rest of the groove, allowing the sensor tube to absorb length errors and facilitating easier embedding, while maintaining sensing accuracy by positioning the expansion groove outside the bumper beam and only expanding in the cross-sectional direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor tube length is precisely controlled to fit the groove, then the sensing accuracy is improved, but the assembly difficulty increases due to length errors
Solution Approach 1:
The groove width parameter is changed by introducing an expansion groove portion with greater width than the standard groove portion. This parameter change allows the groove to accommodate sensor tubes with length variations, absorbing dimensional errors without affecting the sensing accuracy in the measurement direction.
Solution Approach 2:
The groove is segmented into two functional portions: a standard groove portion that maintains sensing accuracy and an expansion groove portion that absorbs length errors. This segmentation allows each portion to fulfill its specific function independently, resolving the contradiction between precision and assembly ease.
2Ease of operation
If the groove width is increased to accommodate length errors, then the assembly ease is improved, but the sensing accuracy may be affected
Solution Approach 1:
Different portions of the groove have different width qualities: the standard groove portion maintains a precise width for accurate sensing, while the expansion groove portion has a greater width to absorb length errors. This local differentiation of groove width quality allows the structure to simultaneously achieve assembly ease and sensing accuracy.
Solution Approach 2:
The groove is divided into a standard groove portion for precision sensing and an expansion groove portion for error absorption. This segmentation ensures that the width increase for assembly ease does not compromise the sensing accuracy in the critical measurement region.
3Adaptability or versatility
If the expansion groove portion is added to the shock absorber, then the adaptability to length errors is improved, but the device complexity increases
Solution Approach 1:
The groove structure is segmented into standard and expansion portions, allowing the shock absorber to adapt to length errors without requiring a completely different groove design. This segmentation provides adaptability while maintaining a relatively simple overall structure that integrates seamlessly with the existing shock absorber geometry.
Solution Approach 2:
The groove with its expansion portion serves multiple functions: it provides precise positioning for the sensor tube in the standard portion while simultaneously accommodating length variations in the expansion portion. This multi-functionality increases adaptability without proportionally increasing device complexity.
Data Source
AI summary
A sensor arrangement structure that makes a sensor tube easy to arrange is disclosed. The sensor arrangement structure includes a bumper beam; a shock absorber disposed in front of the bumper beam and having a groove; and a contact sensor including a sensor tube, in which the sensor tube is disposed between the bumper beam and the shock absorber, the groove is configured to arrange the sensor tube, the groove includes an expansion groove portion, and the expansion groove portion has a width greater than a width of a rest part of the groove.