Ultrasonic Sensor Assembly Automation via Modular Segmentation

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Solution Overview

Problem

The existing ultrasonic sensor assembly is complex and difficult to assemble accurately due to its manual assembly process, which increases manufacturing costs and complexity, especially when connecting the PCB to the lead wire and coating the sound-absorbing material.

Innovation Solution

The ultrasonic sensor assembly features a hollow housing with a through hole and an open end accommodating port, allowing for easy assembly of components like the piezo-electric element, PCB, and sound-absorbing material, with a fixing member and ring rubber for secure alignment and protection, enabling automation of the assembly process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the existing ultrasonic sensor assembly structure is used, then the sensor functionality is maintained, but the assembly process becomes complex and difficult to assemble accurately

Engineering Contradiction:

Improveassembly processVSAvoidassembly structure

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The sensor assembly is divided into distinct modular components: a housing assembly containing the piezoelectric element and sound-absorbing material, a separate PCB assembly with connection terminals, and a mounting bracket. These segmented modules can be manufactured independently and then easily assembled together, reducing overall assembly complexity while maintaining functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A mounting bracket serves as an intermediary component that facilitates the connection between the housing assembly and the PCB assembly. This intermediate element provides alignment features and connection points, making the assembly process more straightforward and accurate without requiring complex direct integration.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If manual assembly process is used for connecting PCB to lead wire and coating sound-absorbing material, then assembly flexibility is maintained, but manufacturing costs increase

Engineering Contradiction:

Improvemanufacturing costVSAvoidassembly process

Core Design Contradiction:

Ease of manufactureVSExtent of automation

Solution Approach 1:

The sound-absorbing material is pre-coated onto the housing interior surface before final assembly, and the PCB connection terminals are pre-positioned with alignment features. These preliminary actions eliminate the need for costly manual operations during final assembly, enabling automated manufacturing processes while controlling costs.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manual mechanical connection process between PCB and lead wire is replaced with an automated electrical connection system using pre-positioned connection terminals and conductive adhesives. This substitution eliminates manual labor requirements and enables automated assembly lines, reducing manufacturing costs while maintaining assembly flexibility.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If the housing top is closed structure, then protection is provided, but element assembly becomes difficult

Engineering Contradiction:

Improveelement assemblyVSAvoidhousing protection

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

Instead of assembling elements from the bottom up through a closed housing, the design inverts the assembly approach by providing open access at the top of the housing. Elements such as the piezoelectric element and sound-absorbing material can be installed from the top opening, then the housing is sealed to provide protection. This inverted assembly sequence simplifies element installation while maintaining protective enclosure.

Inventive Principle:

Principle #13The other way round (Inversion)

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 design simplifies the assembly process, reduces manufacturing costs, and ensures accurate alignment and secure connection of components, facilitating an automated assembly method while maintaining the sensor's functionality.

Implementation Method 1

Fast vibrations equal to the number of frequencies are caused by applying high-frequency electric energy to a ceramic element, in which case when the applied frequency is 20 KHz or higher, the ceramic element generates an inaudible ultrasonic wave having a specific frequency band according to the vibrations

Methodology Applied

Scientific EffectPiezo-electric effect: Piezoelectric Effect

Implementation Method 2

a sound absorbing material 50 that maintains a constant attenuation of a vibration of the case 10

Methodology Applied

Scientific EffectSound absorption: Acoustic Absorption

Data Source

PatentUS9339846B2Ultrasonic sensor assembly

Publication Date: 2016.05.17 HYUNDAI MOBIS CO LTD

AI summary

Provided is an ultrasonic sensor assembly. The present invention simplifies an assembly structure of the ultrasonic sensor assembly, and thus enables a process of the ultrasonic sensor assembly to be performed as an automation process.