Wheel Speed Sensor Cover Crimping Design
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Solution Overview
Problem
Conventional wheel speed sensors experience unnecessary deformation during crimping of the metallic cover, which can lead to installation difficulties due to excessive deformation and potential detachment issues.
Innovation Solution
A wheel speed sensor design featuring a tube-shaped metallic cover with protruding pieces that are crimped towards the sensor head, rather than crimping over the entire circumference, to minimize deformation and ensure secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If crimping is performed over the entire circumference of the opening portion of the metallic cover, then the cover is securely fixed to the sensor head, but unnecessary deformation occurs in portions of the cover other than the crimping portion
Solution Approach 1:
The continuous crimping operation is segmented into discrete crimping positions. Instead of crimping the entire circumference continuously, the invention applies crimping force at multiple separate positions around the opening portion. This segmentation allows the cover to be securely fixed while minimizing cumulative deformation effects, as each crimping position deforms only a localized portion of the cover rather than the entire circumference.
Solution Approach 2:
The crimping force is applied locally at specific positions around the opening portion rather than uniformly across the entire circumference. By concentrating the crimping action at discrete locations, the invention achieves adequate fixation reliability at those specific points while leaving other portions of the cover undeformed, thus maintaining the overall shape and reducing unnecessary deformation.
2Ease of operation
If the cover is made highly deformable to facilitate crimping, then installation becomes easier, but structural integrity and protection capability are compromised
Solution Approach 1:
The crimping process is divided into multiple discrete positions around the cover's opening. This segmentation allows the cover to be deformed incrementally at each position rather than requiring high deformability throughout the entire structure. The cover maintains its overall structural integrity while being sufficiently deformable at the crimping locations to facilitate installation.
Solution Approach 2:
Instead of crimping the entire circumference which would require excessive deformation capability, the invention applies crimping force partially at multiple discrete positions. This partial action approach achieves adequate fixation without requiring the cover material to be highly deformable, thus preserving structural integrity while still enabling easy installation.
Data Source
AI summary
A wheel speed sensor is provided that makes it possible to suppress unnecessary deformation when crimping a cover. A wheel speed sensor has a sensor head in which a sensor is accommodated, and a tube-shaped metallic cover that covers a portion of the sensor head and protects the sensor head. The cover has multiple protruding pieces on an opening portion, and is fixed against the sensor head by the protruding pieces being crimped toward the sensor head.