Universal Wheel Speed Sensor Blind Insertion Design
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Solution Overview
Problem
Commercial vehicles require multiple configurations of wheel speed sensors due to different wheel end configurations, leading to potential incorrect installations and increased costs for design, manufacturing, and inventory management.
Innovation Solution
A universal wheel speed sensor with an overmolded body, a cylindrical metallic canister, and a cable that is sized to be blindly insertable through a bore in a mounting apparatus, allowing it to fit various wheel end configurations without interference and eliminating the need for separate right angle and straight sensor variants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple configurations of wheel speed sensors are used to fit different wheel end configurations, then the sensor can be installed in various wheel end assemblies, but the device complexity and inventory management complexity increase
Solution Approach 1:
The sensor body is designed with a universal geometry where the head zone diameter is equal to or smaller than the coil zone diameter, allowing a single sensor configuration to be installed in multiple different wheel end assemblies through the bore without requiring multiple specialized sensor variants
2Adaptability or versatility
If multiple configurations of wheel speed sensors are maintained, then different wheel end assemblies can be serviced, but the manufacturing cost and inventory cost increase
Solution Approach 1:
A single universal sensor design replaces multiple configuration-specific sensors, simplifying manufacturing processes and reducing inventory complexity while maintaining the ability to service different wheel end assembly types
3Ease of operation
If the sensor body diameter is reduced to fit through the bore, then the sensor can be blindly insertable, but the sensor may not be close enough to the exciter ring for effective signal generation
Solution Approach 1:
The sensor body has non-uniform diameter distribution with the head zone having equal or smaller diameter than the coil zone, allowing the head to pass through the bore while the coil zone extends close to the exciter ring for effective signal generation
Solution Approach 2:
The sensor design utilizes axial extension of the coil zone beyond the head zone to achieve proximity to the exciter ring while maintaining a reduced head zone diameter for bore passage, solving the contradiction through dimensional arrangement
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
The universal sensor simplifies installations by being adaptable to multiple configurations, reducing the risk of incorrect installations and lowering costs by eliminating the need for multiple sensor variants, while ensuring effective signal transmission without interference with wheel end components.
Implementation Method 1
a coil zone (16). The coil zone (16) is encapsulated in a cylindrical metallic canister (18)
Data Source
AI summary
A wheel speed sensor comprises a body, the body being overmolded and having a head zone and a coil zone. The wheel speed sensor also includes a cylindrical metallic canister fitted on the coil zone of the body, wherein the head zone has an equal or smaller diameter than the cylindrical metallic canister. The wheel speed sensor also comprises a cable, wherein the cable extends from the head zone. The wheel speed sensor is sized to be blindly insertable entirely through a bore in an associated mounting apparatus.