Vehicle Suspension Joint with Integrated Sensor Housing
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Solution Overview
Problem
Existing joints for vehicle wheel suspensions require complex assembly processes and suffer from inaccuracies in angular position measurement due to the large distance between sensor elements and magnets, which complicates the integration of sensor devices within structural constraints.
Innovation Solution
A joint with a sensor device integrated into the joint housing produced by assembly injection-molding, where the sensor element is either overmolded or positioned in a recess within the housing, eliminating the need for a ball socket and reducing the distance between the sensor and joint body, allowing for direct fitting and simplified assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a ball socket is fitted into the joint housing to form a bearing for the joint body, then the joint components can be connected movably, but the assembly complexity increases due to additional assembly steps
Solution Approach 1:
The patent combines the bearing function and the housing structure into a single integrated joint housing. The housing directly forms the bearing surface for the joint body through its geometry, eliminating the need for a separate ball socket component. This merging of functions reduces the number of parts and simplifies the assembly process while maintaining the movable connection between joint components.
2Measurement precision
If the sensor element is fixed into a closing cover of the housing, then the sensor device can be integrated, but the distance between sensor element and magnet becomes large, reducing measurement accuracy
Solution Approach 1:
The sensor element is integrated into the housing structure during the molding process itself, rather than being added as a separate component afterward. The housing is molded with an integrated sensor mounting feature that positions the sensor element close to the joint body. This preliminary integration ensures minimal distance between sensor and magnet while simplifying the overall assembly process.
3Ease of manufacture
If a closing cover is used to fix the sensor element, then the sensor device can be mounted, but additional assembly steps are required increasing complexity
Solution Approach 1:
The patent merges the housing structure and sensor mounting function into a single integrated component. The housing is molded with built-in features that directly hold the sensor element in the correct position, eliminating the need for a separate closing cover and reducing the number of assembly steps required for sensor integration.
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 approach simplifies the assembly process, enhances measurement accuracy by minimizing the distance between sensor elements and joint bodies, and allows for the use of alternative measurement methods like incremental transducers, reducing assembly complexity and surface irregularities.
Implementation Method 1
a joint housing produced by an assembly injection-molding process
Implementation Method 2
a magnetic field sensor measures the angle for example between a spherical joint body of a first joint component and a housing of a second joint component of the joint, in that the magnetic field sensor built into a closing cover of the housing evaluates the magnetic field of a magnet fitted into the joint body
Data Source
AI summary
A joint (10) with first and second joint components (12, 26; 19) are movably connected to one another. The first joint component (12, 26) has a spherical joint body (14, 28) and the second joint component (19) rotatably and pivotably holds the joint body (14, 28). A sensor device, for determining the position of the first and second joint components (12, 26; 19) relative to one another, is arranged on the joint (10). The sensor device has at least one sensor element (21, 31) which can be integrated in a housing (18) that is produced by an assembly overmolding process. The joint housing (18) forms the second joint component (19) in which the joint body (14, 28) is directly supported.