Airbag Crash Sensor Housing
A Remote Acceleration Sensor, or RAS, is a device used in automotive airbag systems to help detect crashes. Multiple RAS’s are placed in key positions throughout a vehicle. Sending thousands of signals per second, these devices must remain in constant communication with the central airbag control unit. Therefore it is no surprise that the highest quality of materials and manufacturing is required to produce the housings and connectors for these critical sensors.
Our Approach
We worked from the earliest concept sketches, through prototype, and finally to manufacturing. Thanks to our expertise in producing eye of the needle compliant pins and our insert molding capabilities we ultimately developed a zero defect manufacturing cell to produce this component. Using eye of the needle compliant pins provided a means of terminating the circuit board without the need for soldering. Our component functions as a housing, a mounting bracket, and a connector for the sensor’s electronics.
Materials
- Compliant pins: 510 Phosphor Bronze with Select Gold Plate over Nickel
- Insert bushings/sleeves: Aluminum 6061 T6
- Molding material: Nylon 6, 30% glass filled
Results
- Integrating the connector and housing into one component resulted in a combined average annual savings of over $70,000 per year over previous designs.
- Eye of the needle compliant pin integration improved PPM levels at the final assembly by eliminating the soldering process at the circuit board through holes.
- In line with the European Union’s Restriction of Hazardous Substances Directive, solderless termination helped the OEM toward eliminating lead from their plants in Europe.