Stamped Ground Connection for Temperature Measurement
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Solution Overview
Problem
Current temperature measurement and ground connection methods for control units in motor vehicles are complex, costly, and prone to faults, with existing solutions either overheating the control unit or leading to measurement errors due to heat dissipation issues.
Innovation Solution
A device that integrates a temperature sensor and ground connection using a stamped part with heat and current conducting tongues, where the heat path is separated from the current path, allowing for a simple and cost-effective installation that eliminates the need for external sensors and cables, and ensures accurate temperature measurement and secure electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a temperature sensor is mounted on the transmission or clutch with external wiring and plug connections, then temperature measurement is achieved, but the installation becomes complex and expensive and faults frequently occur
Solution Approach 1:
The patent combines the temperature sensor, its wiring, and the ground connection into an integrated control unit assembly. The temperature sensor is mounted directly on the control unit housing with internal wiring connections, eliminating external plug connections and reducing installation complexity while maintaining measurement functionality.
Solution Approach 2:
The control unit housing serves multiple functions: it protects electronic components, provides a mounting surface for the temperature sensor, acts as a heat dissipation path, and establishes ground connections. This multi-functionality eliminates the need for separate external components and simplifies the overall system.
2Reliability
If a ground connection is realized by cables, braided copper strips or sheet metal lugs attached in a separate work step, then electrical ground connection is achieved, but the solution becomes technically complex and expensive
Solution Approach 1:
The ground connection is integrated into the control unit housing structure itself. The housing includes built-in ground connection elements that are formed as part of the housing manufacturing process, eliminating the need for separate attachment steps and reducing overall system complexity while ensuring reliable electrical grounding.
Solution Approach 2:
The ground connection elements are pre-integrated into the housing during manufacturing before the control unit is installed. This preliminary integration ensures that ground connections are automatically established when the control unit is mounted, eliminating the need for separate ground connection installation steps.
3Measurement precision
If the base plate of the housing is connected over a large area and in a thermally conductive manner to the unit to be monitored, then temperature measurement is achieved, but the control unit overheats and can lead to malfunctions and damage
Solution Approach 1:
The housing connection area is segmented into distinct thermal zones. The mounting sleeve and specific housing sections have controlled thermal conductivity to allow temperature sensing while preventing excessive heat transfer to the control unit electronics. This segmentation enables selective thermal management different parts of the housing.
Solution Approach 2:
Different sections of the housing have different thermal properties. The area in contact with the temperature sensor maintains good thermal coupling for accurate measurement, while other areas are designed with reduced thermal conductivity to protect sensitive electronics from overheating. This local differentiation of thermal quality resolves the contradiction between measurement accuracy and thermal protection.
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 solution provides a simple, space-saving, and cost-effective method for temperature measurement and ground connection, reducing the risk of faults and overheating, while allowing for optimal heat and current path separation, thus ensuring reliable operation of control units in motor vehicles.
Implementation Method 1
a temperature sensor (4) which is arranged in the housing (1, 9) and which has a line (5) which is arranged on the carrier plate (3)
Implementation Method 2
a heat and current conducting connection (7) which is attached to a mounting sleeve (6) which is attached to a lower housing part (1) of the housing (1, 9)
Implementation Method 3
a first tongue (7a) which serves as a heat path
Implementation Method 4
a second tongue (7b) which serves as a current path and by means of which a ground connection of the control unit is ensured
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The apparatus has a temperature sensor (4) mounted on a carrier plate (3) of the control device and between the control unit and a measuring unit, particularly the transmission or a coupling. A heat and electricity conducting connection (7) is provided such that a temperature of the measuring unit is measured from the temperature sensor. The heat and electricity conducting connection is executed as a stamped part, which is pressed onto a mounting sleeve (6) of a housing (1) of the control device.