Vehicle Speed Sensor Cable Exit Design for Flexible Routing
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Solution Overview
Problem
Conventional vehicle speed sensors require meticulous cable routing due to specific installation requirements, limiting flexibility and applicability, especially when newer sensor elements like magnetoresistive sensors need precise orientation.
Innovation Solution
A vehicle speed sensor with a cylindrical housing and a bending limiting element that restricts the radius of curvature of the connection cable, allowing flexible cable routing and protection against mechanical loosening, manufactured through overmolding with a plastic material and a bending limiter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional speed sensors are used with axial or radial heads, then the sensor structure is simple and easy to manufacture, but the cable routing is restricted and installation flexibility is reduced
Solution Approach 1:
The sensor housing is divided into a first housing portion and a second housing portion that can rotate relative to each other about the sensor element. This segmentation allows the cable exit direction to be independently adjusted from the sensor element orientation, enabling flexible cable routing while maintaining a simple overall sensor structure.
Solution Approach 2:
The second housing portion is designed to be rotatable relative to the first housing portion, introducing dynamic adjustability to the cable exit direction. This rotational freedom allows the cable to be routed in various directions without changing the sensor element's fixed orientation, resolving the contradiction between structural simplicity and routing flexibility.
2Ease of manufacture
If the sensor element is fixed in the housing, then the manufacturing process is simple, but the sensor element cannot be adjusted relative to the rotor for precise orientation
Solution Approach 1:
The rotatable second housing portion enables post-installation adjustment of the cable exit direction without affecting the sensor element's fixed position. This dynamic feature allows precise orientation adjustment relative to the rotor while keeping the manufacturing process simple, as the sensor element itself remains fixed during assembly.
Solution Approach 2:
By separating the housing into two rotatable portions, the invention decouples the sensor element fixation (simple manufacturing) from the cable routing adjustment (precision orientation). The first housing portion secures the sensor element, while the second housing portion provides adjustment capability for precise alignment.
3Reliability
If the cable is routed along the shaft with strict routing requirements, then the sensor operation is reliable, but the installation space requirements increase and adaptability decreases
Solution Approach 1:
The rotatable second housing portion allows the cable exit direction to be dynamically adjusted to match different installation scenarios. This ensures reliable sensor operation by maintaining proper cable routing while adapting to various installation spaces and configurations, thereby improving installation adaptability without compromising reliability.
Solution Approach 2:
The rotatable housing design makes the sensor universal for multiple installation positions and cable routing configurations. The same sensor can be adapted to different applications by simply rotating the second housing portion, eliminating the need for multiple specialized sensor variants and increasing installation adaptability while maintaining reliable operation.
Data Source
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AI summary
A vehicle rotational speed sensor comprises a sensor element (110), a cylindrical sensor housing (120) in which the sensor element (120) is housed, an electrical connection cable (130) which leads out of the sensor housing (120), and a bending limiting element (140) which is designed to limit a radius of curvature (R) of the connection cable (130) directly in a lead-out region of the connection cable (130) out of the cylindrical sensor housing (120).