Electric Valve Sensor Mounting With Lead Wire Sandwiching
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Solution Overview
Problem
The existing methods for fixing a rotation sensor to an electric valve, such as insert molding and wire connection, incur high mold costs and equipment costs, and require complex assembly processes.
Innovation Solution
The electric valve design includes a mounting portion with sandwiching portions for the lead wire and a cover that holds the rotation sensor, allowing for simplified assembly by inserting the lead wire and sensor into these portions, and features outflow portions to control resin flow, reducing equipment costs and facilitating assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two-color molding is performed to protect the rotation sensor during insert molding, then the rotation sensor can withstand high temperature molding, but mold cost and man-hours increase
Solution Approach 1:
The cover is divided into two functional regions: a first region (mounting portion) where the rotation sensor is mounted, and a second region (wiring portion) where the lead wire is connected. This segmentation allows each region to be optimized for its specific function, with the first region providing sensor protection and mounting, while the second region handles electrical connections, eliminating the need for complex two-color molding.
2Reliability
If laser welding, resistance welding, or crimping is used to connect the lead wire to wiring portion, then reliable electrical connection is achieved, but processing equipment must be introduced increasing manufacturing costs
Solution Approach 1:
The connection between the lead wire and wiring portion is achieved through a integrated snap-fit structure where the lead wire is inserted into a groove in the wiring portion and held in place by elastic deformation of the wiring portion material. This merging of connection and mounting functions into a single structural feature eliminates the need for separate welding or crimping equipment.
Solution Approach 2:
The wiring portion's elastic material properties enable it to automatically clamp and secure the lead wire through its own deformation, without requiring external welding or crimping equipment. The structure self-secures the electrical connection through its inherent mechanical properties.
3Ease of manufacture
If the cover structure is simplified to reduce manufacturing complexity, then assembly work is facilitated and equipment costs are reduced, but the ability to hold the rotation sensor and manage resin flow may be compromised
Solution Approach 1:
The cover is segmented into a first region for sensor mounting and a second region for wiring, with each region having specialized structural features. The first region includes a mounting portion with through-holes for sensor fixation, while the second region has grooves for lead wire management, allowing simple overall structure with targeted functional complexity.
Solution Approach 2:
Resin is used as an intermediary material to fill the mounting portion and secure the rotation sensor in place, providing stable mounting without requiring complex mechanical fastening structures. The resin also serves as a mediator to manage and contain the flow of material during the molding process.
Data Source
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AI summary
An electric valve 100 according to the present invention includes: a mounting portion 111 to which a rotation sensor 101 having a sensor main body 103 and a lead wire 102 is to be mounted; and input/output wiring portions 130 of which at least a part is arranged in the mounting portion 111 and to which the lead wire 102 is connected, wherein the wiring portions 130 have sandwiching portions 131 that sandwich the lead wire 102.