Abstract: A rotor for use in a rotary position sensor includes an opening designed to receive a shaft having a flat. The rotor has a wedge within the opening designed to engage the shaft firmly but minimize insertion forces. Several troughs running parallel to the shaft and adjacent to the wedge aid in retention by adding a controlled amount of resilience to the rotor. On a shaft receiving end of the rotor there is an additional taper to help with coaxial alignment of the rotor opening and the shaft. On the shaft exiting end there is a half-moon like configuration designed to provide a force opposing surface during shaft insertion while not adversely impacting either the full insertion of the shaft or potential drag between the rotor and the sensor housing. The rotor is designed to offer unique advantage in insertion force to install the rotor on the shaft, while retention force and potential drag against the position sensor housing are minimized.

Abstract: A two stage process of ultrasonic welding is disclosed wherein a first stage determines the amount of displacement required to produce a desired compressive force upon a seal or spring. This displacement is sent to a second stage where the desired displacement is achieved through ultrasonic bonding.In an alternative embodiment, the first stage determines the amount of displacement required to achieve non-compressive contact between the gasket (seal) and the component. This displacement is summed with an empirically determined displacement required to obtain a desired compressive force upon the gasket. The summed displacement is used as the desired displacement for the second stage.