An anti-fraying and corrosion-resistant sensor aviation plug structure

Abstract

The utility model relates to sensor connection technical field especially relates to a kind of anti-wire-breakage corrosion-resistant sensor aviation plug structure, including aviation plug body, still including skin protective layer and buckle device, skin protective layer is covered in the outside of aviation plug body, buckle device is set on the upper surface of sensor, for the fixation of aviation plug body;The utility model uses galvanized metal material to make internal pin, makes full use of the chemical stability of zinc, effectively resists the erosion of humid environment and corrosive medium, fundamentally avoids the contact failure and signal interruption problem caused by metal oxidation, by the thorough sealing of sensor skin protective layer, prevent moisture and dust from entering, ensure that the connection environment of plug line is dry, clean, innovatively set up mechanical buckle fixing mechanism in the right upper corner of plug, form firm mechanical locking, effectively prevent the plug from loosening due to external force pulling, equipment movement or vibration, guarantee connection continues stable.

Description

Technical Field

[0001] This utility model relates to the field of sensor connection technology, and in particular to a sensor aviation plug structure that is resistant to wire breakage and corrosion. Background Technology

[0002] Sensors play a vital role in fields such as industrial automation, coal mine safety monitoring, and environmental monitoring. Their stability and reliability are directly related to the operational safety and efficiency of the entire system. As a key component for the electrical connection between sensors and systems, the performance of aviation connectors directly affects the quality and continuity of signal transmission.

[0003] Traditional aviation sensor connectors often use copper for the internal pins. While copper has good conductivity, it is highly susceptible to oxidation and corrosion in humid, dusty, and corrosive industrial environments. This leads to increased contact resistance, resulting in unstable signal transmission, frequent sensor restarts, and even complete disconnection. Furthermore, traditional aviation connectors have poor sealing, often relying on simple rubber or plastic sleeves for protection. The lack of effective multi-layer sealing allows moisture and dust to easily penetrate through interface gaps, further exacerbating corrosion of metal components and increasing the risk of short circuits, severely impacting sensor lifespan and measurement accuracy. On the other hand, in environments like coal mines where sensors are frequently moved, the lack of mechanical locking mechanisms between the connector and sensor interface, relying solely on insertion and extraction force to maintain the connection, makes the connector prone to loosening or detachment during equipment movement or vibration due to cable pulling. This can cause signal interruption and even production safety accidents. Although some waterproof, dustproof, or ruggedized connector designs exist, they generally suffer from complex structures, high costs, and inconvenient maintenance, failing to achieve long-term stable connections in harsh environments.

[0004] Therefore, given that existing aviation connectors use copper pins, which are prone to oxidation and rust in humid environments, and lack effective sealing of the outer protective layer, making them susceptible to water and dust ingress, and signal interruption due to pulling during sensor movement, a new type of sensor aviation connector structure that is resistant to wire breakage and corrosion can be designed. This new connector uses galvanized metal for the internal pins, effectively resisting erosion from humid environments and corrosive media, fundamentally avoiding contact problems and signal interruptions caused by metal oxidation. The sealed protective layer effectively prevents the intrusion of moisture and dust, improving the sensor's contact reliability. The snap-fit ​​design ensures good contact during sensor movement, reducing wire breakage problems caused by poor contact. Utility Model Content

[0005] To overcome the problems of existing aviation plugs being prone to oxidation and rust in humid environments, easy for water and dust to enter, and easy for signal interruption due to pulling when moving sensors.

[0006] The technical solution of this utility model is: a sensor aviation plug structure that is resistant to wire breakage and corrosion, including an aviation plug body, an outer protective layer and a snap-fit ​​device. The outer protective layer covers the outside of the aviation plug body, and the snap-fit ​​device is set on the upper surface of the sensor for fixing the aviation plug body.

[0007] Preferably, an aviation plug body with an internal 4-pin plug post structure is selected. The plug posts are made of galvanized material, and the outer protective layer is wrapped around the outside of the aviation plug body. The complete seal between the plug body and the outer protective layer is achieved through injection molding or glue sealing process to ensure no gaps and prevent moisture and dust from entering. The snap-fit ​​device is fixed to the preset position on the upper surface of the sensor to ensure that it is firmly installed and accurately positioned. The aviation plug body is inserted into the receiving space of the snap-fit ​​device to ensure that the aviation plug body is firmly clamped to prevent the plug from loosening during vibration or movement. The sensor is connected for power-on testing to verify the stability of signal transmission and ensure that there are no broken wires or poor contacts. The assembled sensor aviation plug is installed in the actual use environment for final debugging to confirm that it can work reliably under different working conditions.

[0008] Preferably, the aviation plug body has a 4-pin plug post structure, and the plug posts are made of galvanized material.

[0009] Preferably, the latching device includes a latching base and a latching arm. The latching arm is provided at the upper end of the latching base and can be opened and closed. The latching base and the latching arm together form a space for accommodating the aviation plug body, and the space is adapted to the size of the aviation plug body.

[0010] Preferably, one end of the locking arm is rotatably connected to the locking base via a pin or hinge, and the other end is fixedly connected to the locking base via fasteners.

[0011] Preferably, the upper ends of both sides of the buckle base are fixedly connected to support columns, and the upper ends of the support columns are rotatably connected to locking blocks. The support columns and locking blocks have damping characteristics. The buckle arm is provided with a through groove that matches the locking block. The buckle arm and the buckle base are detachably connected through the locking block.

[0012] As a preferred option, the inner wall of the arm is equipped with an anti-slip pad.

[0013] Preferably, the outer protective layer is sealed using injection molding or adhesive sealing processes.

[0014] The beneficial effects of this utility model are as follows: The internal pins are made of galvanized metal material, fully utilizing the chemical stability of zinc to effectively resist corrosion from humid environments and corrosive media. This fundamentally avoids contact problems and signal interruptions caused by metal oxidation, significantly improving the reliability and service life of the electrical connection. By thoroughly sealing the sensor's outer protective layer, moisture and dust are prevented from entering, ensuring a dry and clean connection environment for the plug wires, thus improving the sensor's stability and service life. Ensuring the connection interface is always dry and clean further enhances the sensor's adaptability to harsh environments. An innovative mechanical locking mechanism is set at the upper right corner of the plug, forming a firm mechanical lock that effectively prevents the plug from loosening due to external pulling, equipment movement, or vibration, ensuring a continuous and stable connection. These structural improvements complement each other, forming a complete high-reliability connection solution. This not only significantly reduces the sensor failure rate and minimizes system restarts and production interruptions caused by signal problems, but also greatly reduces maintenance frequency and replacement costs, extending the overall equipment's service life. It is particularly suitable for applications with extremely high requirements for equipment reliability and safety, such as coal mines, chemical plants, and field monitoring, and has broad application value. Attached Figure Description

[0015] Figure 1 The diagram shown is a three-dimensional structural schematic of Embodiment 1 of the anti-breakage and corrosion-resistant sensor aviation plug structure of this utility model; Figure 2 The diagram shown is a three-dimensional structural schematic of the snap-fit ​​device in Embodiment 1 of the anti-breakage and anti-corrosion sensor aviation plug structure of this utility model. Figure 3 The diagram shown is a three-dimensional structural schematic of Embodiment 2 of the anti-breakage and corrosion-resistant sensor aviation plug structure of this utility model. Figure 4 The diagram shown is a three-dimensional structural schematic of the snap-fit ​​device in Embodiment 2 of the anti-breakage and anti-corrosion sensor aviation plug structure of this utility model. Explanation of reference numerals in the attached drawings: 1. Aviation plug body; 2. Outer protective layer; 3. Snap-fit ​​device; 31. Snap-fit ​​base; 32. Snap-fit ​​arm; 321. Anti-slip pad; 33. Support column; 34. Locking block. Detailed Implementation

[0016] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0017] Example 1 Please see Figure 1 and Figure 2This utility model provides an embodiment: a sensor aviation plug structure that is resistant to wire breakage and corrosion, including an aviation plug body 1, an outer protective layer 2, and a snap-fit ​​device 3. The outer protective layer 2 covers the outside of the aviation plug body 1, and the snap-fit ​​device 3 is disposed on the upper surface of the sensor for fixing the aviation plug body 1. The aviation plug body 1 is a 4-pin plug post structure, and the plug posts are made of galvanized material. The snap-fit ​​device 3 includes a snap-fit ​​base 31 and a snap-fit ​​arm 32. The snap-fit ​​base 31 is provided with a snap-fit ​​arm 32 at its upper end, and the snap-fit ​​arm 32 can be opened and closed. The snap-fit ​​base 31 and the snap-fit ​​arm 32 together form a space for accommodating the aviation plug body 1, and the space is adapted to the size of the aviation plug body 1. One end of the snap-fit ​​arm 32 is rotatably connected to the snap-fit ​​base 31 by a pin or hinge, and the other end is fixedly connected to the snap-fit ​​base 31 by a fastener. The inner wall of the snap-fit ​​arm 32 is provided with an anti-slip pad 321, and the outer protective layer 2 is sealed by injection molding or glue sealing process.

[0018] The steps for performing the work are as follows: An aviation plug body 1 with an internal 4-pin plug post structure is selected. The plug posts are made of galvanized material. The outer protective layer 2 is wrapped around the outside of the aviation plug body 1. The outer layer 2 is completely sealed to the plug body through injection molding or glue sealing process to ensure no gaps and prevent moisture and dust from entering. The latch base 31 is fixed to the preset position on the upper surface of the sensor to ensure that it is installed firmly and in an accurate position. The aviation plug body 1 is inserted into the receiving space formed by the latch base 31 and the closing latch arm 32 to ensure that the plug and the interface are completely matched. The latch arm 32 is rotated to close, so that it fits against the latch base 31 and is fixed with screws to ensure that the aviation plug body 1 is firmly clamped. It is confirmed that the anti-slip pad 321 on the inner wall of the latch arm 32 is in full contact with the outer surface of the aviation plug body 1 to enhance friction and prevent the plug from loosening during vibration or movement. The sensor is connected for power-on testing to verify the stability of signal transmission and ensure that there are no broken wires or poor contact. The assembled sensor aviation plug is installed in the actual use environment for final debugging to confirm that it can work reliably under different working conditions.

[0019] Example 2 Please see Figure 3 and Figure 4The difference from Embodiment 1 is that the latching device 3 includes a latching base 31 and a latching arm 32. The latching arm 32 is provided at the upper end of the latching base 31 and can be opened and closed. The latching base 31 and the latching arm 32 together form a space for accommodating the aviation plug body 1, and the space is adapted to the size of the aviation plug body 1. Support columns 33 are fixedly connected to the upper ends of both sides of the latching base 31. Locking blocks 34 are rotatably connected to the upper ends of the support columns 33, and there is a damping characteristic between the support columns 33 and the locking blocks 34. The latching arm 32 is provided with a through groove that matches the locking block 34. The latching arm 32 and the latching base 31 are detachably connected through the locking block 34.

[0020] Place the aviation plug body 1 into the receiving space of the latch base 31, ensuring its position is centered and initially aligned with the interface. Hold the latch arm 32 and align it above the latch base 31, then slowly close it, pressing the latch arm 32 down until it completely covers the aviation plug body 1. During the closing process of the latch arm 32, ensure that the through groove on the latch arm 32 is aligned with the locking block 34 on the support post 33. Continue to press down the latch arm 32 so that the locking block 34 is embedded in the through groove. Apply a certain amount of pressure to fully position the latch arm 32. At this point, use the locking mechanism... The damping characteristics between block 34 and support column 33 allow for manual rotation of locking block 34 by approximately 90 degrees to lock it into the through groove, thereby achieving a detachable and secure connection between locking arm 32 and buckle base 31. Slightly shake the aviation plug body 1 and locking arm 32 to confirm that there is no looseness and that locking block 34 is in a locked state, ensuring that the aviation plug will not come out during vibration or movement. When disassembly is required, rotate locking block 34 in the opposite direction until it is aligned with the through groove to release the lock, then lift locking arm 32 upwards to remove aviation plug body 1.

[0021] The sensors from Examples 1 and 2 were applied on a large scale in the safety monitoring system of a large coal mining enterprise. The underground environment of this enterprise is humid and dusty, which places extremely high demands on the reliability of the sensor connectors. The enterprise counted 150 sensor failures from January to October 2024, of which 70 were due to oxidation and rust on the sensor aviation connector wires, with a failure rate of 46.6%. After all the sensors were replaced, the failure rate dropped to 5%.

[0022] This result fully verifies the effectiveness and superiority of the technical solution of this utility model. Specifically: (1) The galvanized pins fundamentally solve the problem of electrochemical corrosion of the core conductive components of the connector.

[0023] (2) The multi-layer sealing structure effectively isolates moisture and dust, providing a dry, clean and stable environment for internal connections.

[0024] (3) The snap-fit ​​design ensures the mechanical connection reliability of the connector in the event of equipment movement or vibration, and avoids signal interruption caused by physical pulling.

[0025] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A sensor aviation plug structure that is resistant to wire breakage and corrosion, comprising an aviation plug body (1), characterized in that: It also includes an outer protective layer (2) and a snap-fit ​​device (3). The outer protective layer (2) covers the outside of the aviation plug body (1), and the snap-fit ​​device (3) is set on the upper surface of the sensor to fix the aviation plug body (1).

2. The sensor aviation plug structure with anti-breakage and anti-corrosion properties according to claim 1, characterized in that: The aviation plug body (1) has a 4-pin plug post structure, and the plug posts are made of galvanized material.

3. The sensor aviation plug structure with anti-breakage and anti-corrosion properties according to claim 2, characterized in that: The latching device (3) includes a latching base (31) and a latching arm (32). The latching base (31) is provided with a latching arm (32) at its upper end, and the latching arm (32) can be opened and closed. The latching base (31) and the latching arm (32) together form a space for accommodating the aviation plug body (1), and the space is adapted to the size of the aviation plug body (1).

4. The sensor aviation plug structure with anti-breakage and anti-corrosion properties according to claim 3, characterized in that: One end of the locking arm (32) is rotatably connected to the locking base (31) by a pin or hinge, and the other end is fixedly connected to the locking base (31) by a fastener.

5. The sensor aviation plug structure with anti-breakage and anti-corrosion properties according to claim 3, characterized in that: The upper ends of both sides of the buckle base (31) are fixedly connected to support columns (33), and the upper ends of the support columns (33) are rotatably connected to locking blocks (34). The support columns (33) and locking blocks (34) have damping characteristics. The buckle arm (32) is provided with a through groove that matches the locking block (34). The buckle arm (32) and the buckle base (31) are detachably connected through the locking block (34).

6. A sensor aviation plug structure with anti-breakage and anti-corrosion properties according to claim 4 or 5, characterized in that: The inner wall of the clamp arm (32) is provided with an anti-slip pad (321).

7. The sensor aviation plug structure with anti-breakage and anti-corrosion properties according to claim 1, characterized in that: The outer protective layer (2) is sealed by injection molding or glue sealing process.

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