Friction Lining Wear Sensor Groove Conductor Segmentation
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Solution Overview
Problem
Existing friction lining wear sensors face challenges with high scrap costs and complex recycling due to the integration of the test conductor during injection molding, which can lead to damage and false alarms during installation and operation.
Innovation Solution
The sensor body features a second groove for the test conductor, allowing it to be inserted separately, with the spring clip inserted over the conductor, reducing scrap costs and enabling easier recycling by allowing only the plastic body to be discarded in case of errors, and providing mechanical protection through the grooves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the test conductor is cast into the plastic material of the sensor body during injection molding, then the sensor provides integrated protection and structural stability, but the manufacturing complexity increases and scrap costs rise significantly
Solution Approach 1:
The sensor is divided into separate components: the plastic sensor body, the test conductor, and the spring clip. Each component is manufactured independently and then assembled together, eliminating the need for complex integrated injection molding while maintaining structural integrity and reliability.
Solution Approach 2:
The test conductor is extracted from the injection molding process and becomes a separate component that is inserted into a groove in the sensor body. This removes the conductor from the molding tool complexity while preserving its protective integration within the sensor assembly.
2Object-affected harmful factors
If the test conductor is cast into the plastic material during injection molding, then mechanical protection is provided, but scrap costs increase due to loss of both plastic and conductor
Solution Approach 1:
By separating the test conductor from the plastic body into distinct components, the system allows selective replacement. Only the inexpensive plastic body needs to be discarded if damaged, while the expensive test conductor can be reused, significantly reducing material loss and scrap costs.
Solution Approach 2:
The design treats the plastic sensor body as a disposable, low-cost component that can be easily replaced, while the expensive test conductor is preserved and reused. This asymmetric replacement strategy minimizes overall material loss.
3Stability of the object's composition
If the test conductor is integrated during injection molding, then structural stability is achieved, but recycling becomes difficult due to composite material complexity
Solution Approach 1:
The sensor is designed as separable components (plastic body, metal spring clip, electrical conductor) that can be easily disassembled. This segmentation maintains structural stability during use while enabling simple separation for recycling, allowing each material to be processed according to its specific requirements.
Solution Approach 2:
The test conductor and spring clip are extracted as separate components from the plastic body. This extraction preserves the structural integrity of the assembled sensor while facilitating easy separation and recycling of individual materials, eliminating the complexity of composite material recycling.
4Ease of operation
If a groove is formed in the sensor body for the spring clip, then easy installation and replacement are enabled, but the risk of test conductor damage during installation increases
Solution Approach 1:
The sensor body includes separate grooves for the spring clip and test conductor, allowing independent insertion paths. This segmentation enables the spring clip to be installed first to provide mechanical stability, followed by careful insertion of the test conductor, reducing damage risk while maintaining ease of installation.
Solution Approach 2:
The spring clip is inserted into its groove first to establish mechanical stability and proper positioning of the sensor body before the test conductor is inserted. This preliminary action creates a stable foundation that protects the more fragile test conductor from damage during subsequent installation steps.
Data Source
Figure 1~2
Figure 3~5
AI summary
The sensor (10) has a sensor body (12) carrying an electrical test conductor (24). The body has a groove (32) inserted into two opposite body side surfaces and surrounding a body point (22) of the body. The groove runs within an area of the body point perpendicular to a bay of the test conductor, and is engaged into a spring clip (36). The sensor body has another groove (20) brought into another body side surface and intersecting the groove (32). The test conductor is guided on a groove base of the groove (20).