Wheel Speed Sensor Assembly With Single-Motion Press-In Mounting
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Solution Overview
Problem
Existing wheel speed sensor assemblies face challenges in efficient and tool-free mounting, particularly in ensuring secure and reliable attachment to vehicle components without complex assembly processes.
Innovation Solution
A wheel speed sensor assembly with a monolithic polymer housing and a press-in fastener that allows for a single axial motion assembly, utilizing a flange and fastener aperture alignment to secure the sensor and fastener into mounting apertures simultaneously, enabling 'plug and play' compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional mounting methods are used for wheel speed sensor assemblies, then secure attachment can be achieved, but the assembly process becomes complex and requires multiple steps and tools
Solution Approach 1:
The sensor housing and flange are merged into a single monolithic polymer component, integrating the mounting function directly into the sensor assembly. This eliminates separate mounting brackets and reduces the number of parts, enabling simpler installation while maintaining secure attachment
Solution Approach 2:
The flange with fastener aperture is pre-formed as an integral part of the sensor housing during manufacturing. The press-in fastener is pre-configured in the flange, so that during installation, only a single axial motion is required to simultaneously insert the sensor and secure it with the fastener, eliminating the need for separate mounting operations
2Ease of manufacture
If a monolithic polymer housing is used, then manufacturing simplicity and cost are improved, but structural strength may be compromised
Solution Approach 1:
The patent specifies that the polymer housing should be constructed from glass-filled nylon or polypropylene, using composite materials that combine the manufacturing advantages of thermoplastics with enhanced mechanical strength through glass fiber reinforcement. This resolves the contradiction by maintaining monolithic construction simplicity while achieving required structural strength
Solution Approach 2:
The sensor housing is segmented into functional zones: a sensor body portion and a flange portion with integrated fastener aperture. This segmentation allows each zone to be optimized for its specific function while remaining part of a single monolithic structure, balancing manufacturing simplicity with structural requirements
3Productivity
If a press-in fastener system is implemented, then assembly speed and tool-free installation are improved, but fastening reliability must be ensured
Solution Approach 1:
The press-in fastener is designed to be self-securing through a single axial pressing motion that simultaneously inserts the fastener into the flange aperture and secures it to the sensor housing. The fastener system is self-contained and requires no additional tools or steps, ensuring both rapid assembly and reliable fastening through the integrated design
Data Source
AI summary
A wheel speed sensor assembly including a sensor having a housing. The housing includes a central body that defines a sensor axis that extends longitudinally through the central body. The housing is constructed of a polymer and includes a first end and a second end opposite the first end. The first end is configured for insertion into a first aperture along the sensor axis. The wheel speed sensor assembly includes a flange disposed proximal to the second end relative to the first end and includes a fastener aperture. The wheel speed sensor assembly includes a press-in fastener engaged with the fastener aperture for mounting in a second mounting aperture along a fastener axis that is parallel to the sensor axis so that the sensor and the press-in fastener can be assembled and secured into the first and second apertures, respectively, with a single assembly motion parallel to the sensor axis.