Spring Clip Sensor Mounting for Tolerance Compensation
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Solution Overview
Problem
Existing sensor mounting technologies for panes, such as rain and light sensors, face complexity in production due to the need to compensate for individual component tolerances, and require intricate assembly and disassembly processes, making them costly and difficult to produce and install securely.
Innovation Solution
A sensor design utilizing a double-sided spring clip with a central, angled spring clip element and outer and inner arms that clamps the sensor module to a carrier plate, allowing for secure attachment and easy assembly/disassembly, with only the printed circuit board and lower part tolerances needing compensation, simplifying production and installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a spring clip acts on the upper part (housing cover) of the sensor module to create a clamp connection, then the sensor can be detachably mounted on the carrier plate, but tolerances of all individual components must be compensated which increases production complexity
Solution Approach 1:
The spring clip is divided into functional segments: a first spring clip element acting on the upper part, a second spring clip element acting on the lower part, and connection elements linking them. This segmentation allows each element to compensate for tolerances in its respective component, reducing the need for complex overall tolerance compensation while enabling detachable mounting.
2Reliability
If a spring clip with multiple arms and elements is used to secure the sensor module, then reliable mounting is achieved, but the assembly and disassembly process becomes more complex
Solution Approach 1:
The spring clip utilizes elastic deformation of its connection elements to enable dynamic assembly and disassembly. During assembly, the connection elements are deformed to allow engagement of the sensor module with the carrier plate. During disassembly, the elastic properties allow the connection elements to be deformed again to release the clamp connection, maintaining reliability while simplifying operations.
3Strength
If a clamp connection is created between the upper part, printed circuit board and lower part, then secure mounting is achieved, but production technology effort increases due to tolerance compensation requirements
Solution Approach 1:
The spring clip applies clamping force locally at two distinct positions: the first spring clip element acts on the upper part while the second spring clip element acts on the lower part. This local quality approach ensures strong mounting at each location independently, allowing each local connection to tolerate component variations without requiring complex overall tolerance compensation, thereby reducing production technology effort.
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 design reduces production complexity and facilitates easy, reliable assembly and disassembly of sensors on panes, ensuring secure mounting with reduced effort in production technology and improved ease of use.
Implementation Method 1
The spring clip (12) is designed to be elastically resilient for this purpose
Data Source
Figure 1a~1b
Figure 1c~1d
AI summary
The invention relates to a sensor (1), particularly a rain sensor and/or light sensor for the purpose of avoiding unnecessary tolerances, having a housing (2) removably attached on carrier plate (10) held on a disk, wherein a spring clamp (12) is provided on the housing (2) and on the carrier plate (10) in an engaging manner for the removable connection. According to the invention, the spring clamp (12) has two outer arms (15) and two inner arms (16) in addition to a central spring clamp element (14), wherein the inner arms (16) engage into the housing (2) through openings (17) provided therein and push against a printed circuit board (7) accommodated in the housing (2), and the outer arms (15) engage into recesses (20) configured on the carrier plate (10). The sensor according to the invention is provided particularly for the automotive industry.