Temperature Sensor Unit with Guided Axial and Rotational Positioning
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Solution Overview
Problem
Existing temperature sensor units suffer from assembly errors due to incorrect axial and rotational positioning of the sensor element within the capsule, which can lead to functional defects and are not easily detectable until installed in equipment, requiring special operator care and lacking preventive measures.
Innovation Solution
A temperature sensor unit with a guided assembly system using radial and longitudinal guides and mechanical/optical verification to ensure precise axial and rotational positioning of the sensor element within the capsule, facilitated by curable resin retention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the sensor element is positioned inside the capsule using a separating element with dimensional constraints, then the radial positioning is guaranteed, but the axial and rotational positioning relies solely on operator skill and is not verifiable
Solution Approach 1:
The patent applies preliminary action by providing guide structures (radial guide and longitudinal guide) and verification features (projections and recesses) during the capsule manufacturing process. These features are pre-formed to automatically guide and verify the sensor element positioning during assembly, eliminating the need for complex verification systems after assembly.
Solution Approach 2:
The patent uses an intermediary approach by introducing guide structures and verification features as intermediate elements between the capsule and sensor element. The radial guide and longitudinal guide act as intermediaries that facilitate correct positioning, while the projections and recesses serve as intermediaries for verification, simplifying the overall assembly process.
2Reliability
If the capsule is filled with resin for fixing the sensor element, then the sensor element is retained, but assembly errors by the operator are not prevented and may go undetected until installation
Solution Approach 1:
The patent implements feedback by incorporating verification features (projections on the separating element that fit into recesses on the capsule) that provide immediate feedback during assembly. When the sensor element is correctly positioned, the projections align with the recesses, confirming proper assembly before the resin is applied, thus preventing errors while maintaining ease of operation.
Solution Approach 2:
The verification features are pre-formed during capsule manufacturing, allowing the operator to verify correct sensor element positioning before the resin curing process. This preliminary verification step ensures reliability without adding complexity to the overall assembly operation.
3Manufacturing precision
If the separating element is introduced manually with precise positioning, then the sensor element can be correctly positioned, but the process requires special operator care and skill
Solution Approach 1:
The patent applies self-service by designing the capsule with self-aligning features (radial guide, longitudinal guide, projections, and recesses) that automatically guide and verify the sensor element positioning during assembly. The structure serves itself by providing built-in alignment and verification mechanisms, eliminating the need for special operator skill while maintaining high positioning precision.
Solution Approach 2:
The guide structures and verification features act as intermediary elements that mediate between the operator's manual assembly action and the precise positioning requirement. These intermediaries translate simple manual insertion into precise, verifiable positioning, making the manufacturing process easier while maintaining accuracy.
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
Ensures correct assembly and easy detection of deviations, preventing defective units from being installed, enhancing reliability and reducing human error in the assembly process.
Implementation Method 1
fixed inside the capsule by means of the injection and curing of a filler, generally defined by epoxy resin
Implementation Method 2
a tubular-shaped capsule, formed in non-electrically conductive polymeric material, such as PS or PVC, having a closed end
Data Source
AI summary
A temperature sensor unit include a capsule and an assembly defined by a separating element and a sensor element, which is housed and retained, by resin, inside the capsule which is provided, at an open end, with a radial guide and, in its interior, with a longitudinal guide, the separating element incorporating laterally a longitudinal guide follower element which carries a radial guide follower element and which is slidably fitted, in the longitudinal guide, until the radial guide follower element is seated on the radial guide, defining the axial and rotational positioning of the sensor element inside the capsule.