Wheel Speed Sensor Lead Frame Connection for Dual-Sensor Assembly
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Solution Overview
Problem
Existing wheel speed sensors face challenges in securing reliable connections between the sensor and cable, particularly in terms of connection quality and process efficiency, and there is a need for improved mounting technologies to efficiently align and connect multiple sensors for enhanced detection accuracy and redundancy.
Innovation Solution
The proposed solution involves a device for sensing wheel speed that includes a wheel speed sensor with lead frames extending outside the sensor body, connected to cables through connection members. This configuration allows for efficient alignment and connection of multiple sensors, utilizing a holder to expose the lead frames and a cable holder to manage the cables effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding methods are used to connect cable to lead frame, then connection strength is improved, but process efficiency deteriorates
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical connection system consisting of a connection member that physically secures the lead frame to the cable. This substitution eliminates the complex welding process while maintaining connection reliability through a simpler mechanical fastening mechanism.
2Measurement precision
If two wheel speed sensors are arranged for each wheel, then detection accuracy is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple wheel speed sensors into a single integrated sensor assembly where two sensor elements are mounted on one holder. This merging approach maintains the detection accuracy benefits of having two sensors while reducing overall system complexity by consolidating mounting structures, cable connections, and housing requirements.
Solution Approach 2:
The connection member and holder structure serve multiple functions simultaneously: they secure the lead frame to the cable, provide structural support for multiple sensor elements, and enable standardized mounting. This multi-functionality reduces the number of separate components needed, thereby reducing device complexity while supporting multiple sensors.
3Ease of operation
If lead frame is exposed to outside through holder, then connection ease is improved, but manufacturing precision requirements increase
Solution Approach 1:
The holder is designed with pre-formed connection structures and positioning features that guide the lead frame and cable into proper alignment during assembly. This preliminary preparation of the holder structure eliminates the need for high-precision alignment operations during final assembly, making the connection process easier while maintaining manufacturing feasibility.
Data Source
AI summary
A device for sensing wheel speed may include a wheel speed sensor having a sensor body with an embedded first sensor element for sensing the wheel speed of a vehicle, and a first lead frame electrically connected to the first sensor element and extending to the outside of the sensor body; a first cable having a first conductive wire electrically connected to the first lead frame and a first sheath surrounding the first conductive wire; and a first connection member arranged to surround the first lead frame and one end of the first conductive wire that is exposed to one end of the first cable and overlaps the first lead frame, and fixing the first lead frame and the first conductive wire in a contact state.