Turbocharger Speed Sensor Segmented Overmolded Seal
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Solution Overview
Problem
Existing speed sensors for turbochargers face challenges in manufacturing due to the need for precise temperature and pressure control during over-molding, which can result in damage or inadequate sealing.
Innovation Solution
The speed sensor is divided into three distinct portions: a first portion with a sensing assembly, a second portion containing a wiring harness, and a third portion that acts as a flange and seal, allowing for separate manufacturing and over-molding to ensure proper alignment and sealing without damaging the components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high temperature and pressure are used for over-molding, then sealing quality is improved, but the speed sensor components may be damaged
Solution Approach 1:
The speed sensor is divided into three distinct portions (sensing assembly, wiring harness, and seal/flange portion) that are manufactured separately and then assembled. This segmentation allows each component to be optimized for its specific manufacturing requirements, enabling the seal portion to withstand high temperature and pressure during over-molding while protecting the sensitive sensing assembly and wiring harness from damage.
2Strength
If low temperature and pressure are used for over-molding, then component damage is prevented, but sealing quality deteriorates
Solution Approach 1:
By separating the seal/flange portion from the sensitive electronic components, the invention enables the seal to be subjected to high temperature and pressure during over-molding to achieve proper sealing, while the sensing assembly and wiring harness are protected from these harsh conditions.
3Productivity
If the speed sensor is manufactured as a single integrated component, then manufacturing steps are reduced, but alignment precision and sealing quality deteriorate
Solution Approach 1:
The speed sensor is divided into three portions that are manufactured separately using optimized processes for each component type, then assembled together. This segmentation enables precise alignment features to be incorporated at each manufacturing stage, ensuring high alignment accuracy in the final assembled product while maintaining manufacturing efficiency through modular production.
Solution Approach 2:
The sensing assembly and wiring harness are pre-assembled and prepared with alignment features before the final assembly with the seal portion. This preliminary preparation ensures that when the components are combined, precise alignment is achieved without requiring complex real-time adjustment during final assembly.
Data Source
AI summary
In an embodiment, a speed sensor includes a first portion, a second portion, and a third portion. The first portion includes a sensing assembly for generating a signal associated with a movement of an object external to the speed sensor. The second portion includes a wiring harness for transferring the generated signal to a device external to the speed sensor. The first portion and the second portion are joined. The third portion is over-molded over a point of the speed sensor where the first portion joins the second portion. Over-molding the third portion at the point may act to seal the point from outside contaminants. Moreover, over-molding the third portion at the point may act to strengthen the speed sensor at the point.