Thermocouple Assembly in Injection Molding Sensors
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Solution Overview
Problem
The existing manufacturing method for measuring devices, such as those used for temperature measurement in injection molding, faces challenges in easily inserting thermocouples into sensor bodies due to similar diameters, leading to difficulties in device assembly and potential deformation issues during welding.
Innovation Solution
The method involves preparing a structure with a housing and a piece having grooves, where the thermocouple is accommodated between the grooves and the housing's inner surface, allowing for easier assembly and positioning, and using welding techniques to enhance bonding strength and prevent deformation, including first welding on the distal end face and optional second welding on the outer peripheral surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the measuring element is inserted into a hole with similar diameter, then the measuring device structure is compact, but the insertion becomes difficult and manufacturing complexity increases
Solution Approach 1:
The measuring element is preliminarily fixed to the front face of the sensor body using a fixing member (such as a clip or clamp) before welding. This preliminary fixation allows the measuring element to be securely held in position during the welding process without requiring tight clearance fits, thereby simplifying insertion while maintaining compact dimensions.
Solution Approach 2:
A fixing member acts as an intermediary between the measuring element and the sensor body. This intermediary component facilitates easy insertion and secure positioning of the measuring element, eliminating the need for precision hole-diameter matching while enabling subsequent welding operations.
2Strength
If welding is performed to fix the measuring element, then bonding strength is improved, but deformation may occur during welding
Solution Approach 1:
The measuring element is preliminarily fixed to the front face using a fixing member before welding. This preliminary fixation stabilizes the measuring element's position and reduces movement during welding, thereby minimizing welding-induced deformation while maintaining strong bonding.
Solution Approach 2:
The fixing member serves as a cushioning element that absorbs and distributes welding heat and mechanical stress. By providing this protective intermediary layer, deformation of the measuring element and sensor body is reduced during the welding process.
3Ease of operation
If the measuring element protrudes from the sensor body, then insertion into the mold hole is facilitated, but the device complexity increases
Solution Approach 1:
The measuring element is integrated with the front face of the sensor body through welding after preliminary fixation. This merging eliminates the need for separate protruding structures while maintaining easy insertion capability, as the measuring element remains accessible at the front face.
Solution Approach 2:
The front face of the sensor body serves multiple functions: it provides a mounting surface for the measuring element, allows insertion into the mold hole, and maintains a compact overall structure. The measuring element itself serves dual purposes of temperature sensing and structural support.
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 manufacturing process, improves the bonding strength and withstand voltage performance of the measuring device, and reduces the risk of deformation, enabling more precise temperature measurement.
Implementation Method 1
a step of fixing the piece to the housing by first welding on a distal end face of the structure
Implementation Method 2
a step of polishing a welded portion formed by the first welding and the distal end face
Data Source
AI summary
A method for manufacturing a measuring device includes: a step of preparing a structure; a step of fixing a piece to a housing by first welding on a distal end face of the structure; and a step of polishing a welded portion formed by the first welding and the distal end face. The structure includes: the housing having a first end and a second end which are open in one direction; a thermocouple extending in the one direction in the housing; and the piece provided in the housing, exposed from the first end, and configured to hold the thermocouple. The piece has a side face facing an inner surface of the housing. In the step of preparing the structure, the thermocouple is accommodated between a pair of grooves provided on the side face and the inner surface of the housing by inserting the piece into the housing.