Ultrasonic Sensor Elastic Holding Member Alignment
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Solution Overview
Problem
Conventional ultrasonic sensors face difficulties in accurately setting the elastic body and case at a prescribed positional relationship during the insertion step, leading to potential misalignment and improper pressure application, which complicates the production process.
Innovation Solution
The ultrasonic sensor design includes a columnar ultrasonic transceiver, a plastic elastic holding member with a cylindrical shape, and a sensor case with an engagement protrusion and recess system, allowing for precise alignment and support through elastic deformation of the leading projection, which promotes the engagement of the engagement protrusion with the recess, ensuring correct positional relationship and secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the elastic holding member is inserted into the sensor case without engagement features, then the insertion process is simple, but the positional relationship between the elastic holding member and sensor case cannot be accurately determined
Solution Approach 1:
The leading projection automatically engages with the engagement protrusion during insertion, and the elastic deformation of the leading projection provides tactile feedback to the operator, enabling self-alignment and accurate positioning without requiring external guidance or complex alignment procedures
Solution Approach 2:
The engagement between the leading projection and engagement protrusion produces a tactile sensation (analogous to visual feedback) that signals to the operator when proper engagement has occurred, allowing accurate determination of the positional relationship during the insertion process
2Stability of the object's composition
If the elastic holding member is made rigid to maintain positional accuracy, then the positional relationship is stable, but the elastic deformation needed for smooth insertion and engagement is lost
Solution Approach 1:
The leading projection is designed with elastic properties that allow it to dynamically adapt during insertion - deforming elastically to pass through the engagement protrusion and then restoring to its original shape to secure the engagement, providing both smooth insertion and stable positioning
Solution Approach 2:
The elastic holding member utilizes changes in its physical state (elastic deformation) during the insertion process, transitioning from a flexible state during insertion to a stable state during operation, thereby achieving both ease of operation and positional stability
3Device complexity
If the engagement protrusion and recess are designed without a leading projection, then the structure is simpler, but the engagement process cannot be smoothly guided and accurate positioning is difficult
Solution Approach 1:
The leading projection is positioned at the base-end side of the support bottom portion to lead the engagement process, making preliminary contact with the engagement protrusion before the main body engages, thereby guiding the insertion and ensuring accurate positioning
Solution Approach 2:
The engagement structure is segmented into distinct functional elements: the leading projection for guidance and initial contact, the engagement protrusion for positioning, and the engagement recess for securing, allowing each element to perform its specific function efficiently
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 configuration enhances workability by allowing accurate determination of the positional relationship and secure attachment of the elastic holding member to the sensor case, improving the production efficiency of ultrasonic sensors.
Implementation Method 1
an elastic holding member that is a plastic elastic member elastically supporting the ultrasonic wave transmitting and receiving device
Data Source
AI summary
An ultrasonic sensor includes an ultrasonic wave transmitting and receiving device, an elastic holding member elastically supporting the ultrasonic wave transmitting and receiving device, and a sensor case housing and holding the elastic holding member. A case cylindrical portion of the sensor case includes an engagement protrusion provided to protrude inward in a radial direction. The elastic holding member includes a support bottom portion in contact with a transmitting-and-receiving-device bottom, an engagement recess provided to be recessed inward in the radial direction and thus house the engagement protrusion, and a leading projection provided at a position corresponding to the engagement recess with respect to a peripheral direction surrounding a central axis line, and provided to protrude from the support bottom portion toward the base-end side in the axial direction. The support bottom portion is formed as a thick portion. The engagement recess is provided in the support bottom portion.