Stroke Sensor Assembly Integrating Mounting and Electrical Connector
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Solution Overview
Problem
Modern vehicle braking systems with electronically controlled braking systems face challenges in accurately detecting piston movement within hydraulic blocks, which affects the determination of appropriate braking force, leading to potential inefficiencies in slowing or stopping the vehicle.
Innovation Solution
A stroke sensor assembly is provided, comprising a stroke sensor, sensor circuit board, and sensor housing with integrally formed electrical connectors and potting material, which is securely mounted to the hydraulic block using a single threaded fastener, allowing for precise detection of piston position and communication with an electronic control unit for appropriate braking force application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If multiple fasteners are used to mount the sensor housing to the hydraulic block, then the mounting stability is improved, but the assembly complexity increases
Solution Approach 1:
The patent consolidates multiple mounting functions into a single fastener by integrating a mounting flange with multiple mounting apertures on the sensor housing. This allows one fastener to secure the sensor assembly to the hydraulic block while maintaining stable mounting through the distributed aperture design.
2Reliability
If separate electrical connectors are used for sensor communication, then the electrical connection reliability is improved, but the device complexity increases
Solution Approach 1:
The electrical connector is integrally formed with the sensor housing as a single piece, eliminating separate connector components. This integrated design maintains reliable electrical connection while reducing device complexity by combining the housing and connector into one element.
3Reliability
If the sensor assembly requires multiple components for mounting and connection, then the functional reliability is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The sensor housing, mounting flange, and electrical connector are designed as an integrated assembly where the mounting flange with multiple apertures and the electrical connector form a unified structure. This reduces the number of separate components that must be precisely aligned during assembly, thereby reducing manufacturing precision requirements while maintaining functional reliability.
Data Source
AI summary
A stroke sensor assembly for a vehicle braking system may include a stroke sensor, a sensor circuit board, and a sensor housing. The stroke sensor may be operable to detect a position of a piston within a hydraulic block. The sensor circuit board may be in communication with the stroke sensor and may be electrically connected to a plurality of terminals. The sensor housing may surround the stroke sensor and the sensor circuit board. The sensor housing may include a single mounting aperture for mounting the sensor housing to the hydraulic block. The sensor housing may include an integrally formed female electrical connector that at least partially houses the terminals. The female electrical connector may include an inlet opening through which a male electrical connector is received for electrical connection with the terminals. The female electrical connector may include one or more ramped surfaces defining the inlet opening.