Sensor Unit Torque Isolation via Molded Part
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Solution Overview
Problem
Existing sensor units face measurement errors and mechanical failures due to torque transmission during connection, which requires complex housing machining and precise alignment, leading to potential clamping effects.
Innovation Solution
A sensor unit design featuring a molded part with a rotationally fixed inner contour that absorbs torque, preventing its transmission to the sensor electronics and sensor, using a separate molded part to redirect torque to the housing, eliminating the need for complex housing processing and ensuring precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If holding surfaces are milled into the housing to transmit torque directly, then torque transmission to the housing is improved, but manufacturing complexity and processing time increase
Solution Approach 1:
The patent divides the torque transmission function into separate components: the housing provides structural support, while a dedicated connection element (such as a flange or bracket) handles torque transmission. This segmentation allows the housing to be manufactured without complex machining, while the connection element can be separately optimized for torque bearing.
Solution Approach 2:
The patent introduces an intermediary connection element that mediates between the housing and the components requiring torque protection. This intermediary absorbs and redirects torques, preventing them from being transmitted to the housing structure and subsequently to sensitive components like sensors or electronics.
2Strength
If holding surfaces are machined into the housing, then torque absorption is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent separates the torque absorption function from the housing manufacturing process by introducing dedicated connection elements. These elements can be manufactured using simpler, more cost-effective processes and then assembled to the housing, reducing overall manufacturing complexity and cost.
Solution Approach 2:
The patent employs connection elements that are designed to be simpler and potentially replaceable, rather than permanently modifying the housing structure. This approach reduces manufacturing costs by avoiding expensive machining operations on the housing itself.
3Manufacturing precision
If precise alignment between socket and holding sections is required, then torque transmission accuracy is improved, but assembly complexity increases
Solution Approach 1:
The patent employs asymmetric design features in the connection elements, such as keyways, splines, or cam mechanisms, that provide self-alignment during assembly. These asymmetric features guide the components into the correct relative positions automatically, eliminating the need for precise pre-alignment and reducing assembly complexity.
Solution Approach 2:
The patent incorporates alignment features that are pre-formed during the manufacturing process of the connection elements. Features such as pre-machined mounting holes, integrated alignment pins, or molded-in positioning structures ensure correct alignment before final assembly, reducing the precision requirements during the assembly process itself.
Data Source
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AI summary
Sensor unit (1) comprising a sensor (3), sensor electronics (5) connected to the sensor (3) and a first connection unit (7) connected to the sensor electronics (5), wherein the sensor (3), the sensor electronics (5) and the first connection unit (7) are arranged in a tubular housing (6) and wherein the first connection unit (7) is contactable with a correspondingly designed second connection unit (9), wherein a molded part with an inner contour (12) is arranged in the housing in a rotationally fixed manner, wherein the inner contour (12) and an outer contour (74) of the first connection unit (7) and/or the second connection unit (9) are formed at least partially corresponding to each other, and the inner contour (12) has at least one retaining section (14) which is designed in such a way as to prevent the first and/or second connection unit (9) from rotating relative to the molded part (10).