Ultrasonic Sensor U-Shaped Circuit Carrier Assembly
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Solution Overview
Problem
The production and assembly of ultrasonic sensors for detecting documents of value are complex due to the need for precise alignment and electrical connection of separate ultrasonic transducers, which increases manufacturing effort and complexity.
Innovation Solution
An ultrasonic sensor design featuring a U-shaped circuit carrier with the ultrasonic transmitter and receiver integrated on the same board, allowing for simplified production and assembly, where the transducers are aligned and connected directly to the control and evaluation circuit, reducing the need for separate housings and complex alignment procedures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate ultrasonic transducers are used and mounted in a housing, then the sensor can detect documents of value, but the production and assembly become complex due to alignment requirements
Solution Approach 1:
The patent combines the ultrasonic transmitter and receiver into a single integrated module mounted on one circuit carrier. This merging eliminates the need for separate mounting and alignment of individual transducers, thereby reducing production complexity while maintaining detection capability.
Solution Approach 2:
The circuit carrier serves multiple functions: it provides electrical connections for both transducers, structural support for mounting, and positioning references for alignment. This multi-functionality reduces the number of separate components needed, simplifying production.
2Reliability
If separate ultrasonic transducers are mounted and aligned, then detection function is achieved, but manufacturing effort increases
Solution Approach 1:
The transducers are pre-mounted and electrically connected on the circuit carrier before final assembly into the housing. This preliminary action allows alignment and connection work to be done in a controlled setting, reducing manufacturing effort during final assembly.
3Reliability
If ultrasonic transducers are aligned and electrically connected separately, then the sensor operates correctly, but assembly time increases
Solution Approach 1:
By integrating both transducers and their electrical connections onto a single circuit carrier, the patent reduces the number of separate assembly operations. The entire module can be installed as one unit, significantly reducing assembly time while ensuring operational correctness through pre-established connections.
4Measurement precision
If multiple separate components are used for ultrasonic detection, then detection precision can be maintained, but the number of parts increases
Solution Approach 1:
The circuit carrier performs multiple functions simultaneously: electrical connection, mechanical support, and alignment reference. This consolidation reduces the total number of parts needed while maintaining detection precision through the preserved functional relationships between transducer elements.
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 manufacturing process, enhances alignment stability, and facilitates a robust sensor housing, resulting in a more efficient and cost-effective production method for ultrasonic sensors.
Implementation Method 1
an ultrasonic transmitter held on one leg section and the ultrasonic receiver held on the other leg section. The ultrasonic transmitter and the ultrasonic receiver thus form an ultrasonic path along which ultrasound is emitted by the ultrasonic transmitter
Data Source
Figure 1~3
Figure 4~6
AI summary
A description is given of an ultrasonic sensor for detecting a valuable document transported through a detection region of the ultrasonic sensor, comprising an ultrasonic transmitter and an ultrasonic receiver, which are arranged such that ultrasound from the ultrasonic transmitter can be emitted into the detection region and ultrasound of the ultrasonic transmitter coming from the detection region can be received by the ultrasonic receiver, comprising a driving and evaluating circuit for driving the ultrasonic transmitter and for detecting and evaluating signals of the ultrasonic receiver and a circuit carrier, on which the driving and evaluation circuit, the ultrasonic transmitter and the ultrasonic receiver and conductor tracks electrically connecting the driving and evaluation circuit to the first and second ultrasonic transducers are held, wherein the circuit carrier is embodied in a U-shaped fashion and has two limb sections connected to one another, and the ultrasonic transmitter is held on one of the two limb sections and the ultrasonic receiver is held on the other of the two limb sections. Furthermore a method for producing the ultrasonic sensor is specified.