Sensor Unit Output Connector Eliminates Soldering

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Solution Overview

Problem

The existing sensor units for bearing assemblies require complex and costly electrical connections through soldering, which prolongs the mounting process and increases costs due to the need for multiple connections.

Innovation Solution

A sensor unit with an output connector that uses mechanical forces to establish electrical connections via plug portions and clamp portions, eliminating the need for soldering or welding by using a connection cable with at least two electrical wires and a connection device with circular holes and elastically deformable plug portions to ensure a pressing contact.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soldering connections are used for electrical connections, then reliable electrical connections are achieved, but the mounting process becomes time-consuming and costly

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmounting time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the thermal/mechanical soldering process with a purely mechanical connection system. The connection pins with clamp portions mechanically secure the wires, and the plug portions insert into circular holes to establish electrical contact through mechanical pressure, eliminating the need for soldering heat and processes while maintaining reliable electrical connections.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connection pins serve as intermediary elements between the wires and the connection device. These pins provide both mechanical support (through clamp portions) and electrical connection (through plug portions), acting as a mediator that simplifies the overall connection process while ensuring reliable electrical contact without requiring complex soldering operations.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If soldering connections are used for electrical connections, then reliable electrical connections are achieved, but the mounting cost increases

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidmounting cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The connection pins appear to be designed as simple, potentially disposable components that can be easily manufactured and replaced. This approach prioritizes low cost and ease of assembly over long-term durability, allowing for quick replacement if needed while keeping the overall system cost low through simplified manufacturing processes.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Adaptability or versatility

If multiple electrical connections are made, then complete electrical functionality is achieved, but the connection complexity increases

Engineering Contradiction:

Improveelectrical functionalityVSAvoidconnection complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent combines multiple connection functions into a single integrated connection act. The connection pins simultaneously provide mechanical wire securing (through clamp portions) and electrical connection (through plug portions), merging what would otherwise be separate operations into one unified mechanical insertion action, thereby reducing overall connection complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The connection pins serve multiple functions: they mechanically clamp the wires, provide structural support, and establish electrical contact through the plug portions. This multi-functionality reduces the need for separate components for each function, simplifying the overall connection system while maintaining complete electrical functionality.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution simplifies the mounting process by allowing plug-and-play connections, reducing costs and time associated with traditional soldering methods while maintaining reliable electrical connections.

Implementation Method 1

Each plug portion comprises a longitudinal slot, which allows said plug portion to elastically deform

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Data Source

PatentUS9482557B2Sensor unit for sensing an angular position of a rotating element with respect to a fixed element and bearing assembly comprising such a sensor unit

Publication Date: 2016.11.01 AB SKF SKF PATENT DEPARTMENT

AI summary

A sensor unit for sensing the angular position of a rotating element with respect to a fixed element includes a target fastened to the rotating element and a given number of sensing cells. Each sensing cell is connected to a connection device adapted to provide power supply, transmit data delivered by the sensing cells and connect each sensing cell to the ground. The sensor unit provides an output connector for electrically connecting the sensor unit to a reception device, a power supply system and the ground, via a connection cable having at least two connection wires. The connector includes, for each wire of the connection cable, a connection pin having a clamp portion adapted to receive an end of the wire, and a plug portion adapted to make a pressing contact with the connection device.