Spot-Welded Sensor Bracket Assembly for Precise Orientation
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Solution Overview
Problem
The existing sensor attachment brackets for vehicles are prone to deformation due to thermal strain from linear welding, leading to inaccurate sensor orientation and increased man-hours for attachment.
Innovation Solution
A sensor attachment bracket with a base bracket and a sensor-mounting-position ensuring bracket formed in a hat shape, joined by spot welding, reducing thermal strain and the number of welded portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If linear welding is used to join the sensor-mounting-position ensuring bracket to the base bracket, then the joint strength is improved, but thermal strain is generated causing deformation and reducing attachment precision
Solution Approach 1:
The patent changes the welding parameter from linear welding to spot welding. This parameter change reduces the heat input and thermal strain while maintaining sufficient joint strength through strategically positioned spot welds at flange portions, thereby preventing bracket deformation and preserving attachment precision.
Solution Approach 2:
The patent segments the continuous linear weld into discrete spot welds at specific flange portions. This segmentation reduces the overall thermal affected zone while maintaining structural integrity at critical joining points, thus minimizing thermal strain-induced deformation.
2Strength
If linear welding is used to join the brackets, then the joint strength is improved, but the number of welded portions increases leading to increased man-hours
Solution Approach 1:
The patent segments the welding operation into a limited number of discrete spot welds at flange portions rather than continuous linear welding. This reduces the total welding time and man-hours required while maintaining sufficient joint strength through strategic placement of spot welds at critical locations.
Solution Approach 2:
The patent applies partial welding action only at the necessary flange portions rather than complete linear welding along the entire bracket interface. This partial action is sufficient to achieve the required joint strength while significantly reducing the time and labor required for attachment.
3Ease of manufacture
If the bracket deforms due to thermal strain, then the manufacturing process is simplified, but the sensor facing direction deviates from the designed direction reducing detection accuracy
Solution Approach 1:
The patent changes the welding parameter from linear welding to spot welding, which reduces thermal strain and prevents bracket deformation. This maintains the sensor's designed facing direction and ensures accurate obstacle detection while still achieving sufficient joint strength through spot welds.
Solution Approach 2:
The patent takes preliminary anti-action by using spot welding methodology that prevents thermal strain-induced deformation before it can affect the sensor orientation. This proactive approach maintains the precision of the sensor's facing direction from the outset.
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
Improves attachment accuracy, reduces man-hours, and minimizes thermal strain, allowing for efficient and precise sensor orientation with reduced components.
Implementation Method 1
a flange portion (53, 51) of the sensor-mounting-position ensuring bracket 5 and the base bracket 4 are joined to each other by spot welding
Implementation Method 2
a sensor-mounting-position ensuring bracket 5 formed by bending a plate-shaped member in a hat shape
Data Source
AI summary
An object of the present disclosure is to provide a sensor attachment bracket and a sensor assembly capable of accurately attaching a sensor. A sensor attachment bracket and a sensor assembly include a base bracket formed of a plate-shaped member and a sensor-mounting-position ensuring bracket formed by bending a plate-shaped member in a hat shape, in which a flange portion of the sensor-mounting-position ensuring bracket and the base bracket are joined by spot welding.