Acoustic Leak Sensor Mounting With Tool-Free Key-and-Track Fastening
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Solution Overview
Problem
Existing systems for attaching sensors to pipes in utility environments, such as water and gas, face challenges like corrosion, difficult installation, contamination, and inconsistent connections due to under- or over-tightening, requiring special tools and multiple technicians, especially in dirty or confined spaces.
Innovation Solution
A mounting system with a clamp and mount design featuring key-and-track or snap-and-recess fastening mechanisms that allow for one-handed sensor attachment with a fraction of a turn, providing secure mechanical and acoustic connections without damaging the sensor, and incorporating audible or tactile feedback for proper installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If magnets are used to make the connection between sensor and pipe, then the installation is simplified, but the connection integrity degrades over time due to oxidation of ferrous material in wet environments
Solution Approach 1:
The patent removes the magnetic component from the mounting system entirely, replacing it with a purely mechanical fastening system using a clamp and set screw. This extraction eliminates the oxidation problem inherent in ferrous magnetic materials while maintaining ease of installation through the simple mechanical design.
Solution Approach 2:
The mounting system uses a simple, replaceable mechanical clamp and set screw assembly that can be easily installed and replaced if needed. The design accepts that the mounting components may need replacement over time but makes this straightforward without complex mechanisms, prioritizing reliability over permanent durability.
2Reliability
If technicians use traditional mounting methods with multiple revolutions of the sensor, then the connection can be secured, but the installation time increases and special tools are required
Solution Approach 1:
The clamp is pre-positioned on the pipe with the sensor already inserted, and the set screw is pre-threaded into the clamp. This preliminary arrangement eliminates the need for multiple revolutions and special tools during installation, as everything is ready for immediate securing with a single tightening action.
Solution Approach 2:
The mounting system is divided into separate functional components: the clamp that attaches to the pipe, the sensor housing, and the set screw for securing. This segmentation allows each component to be optimized independently and assembled quickly without requiring complex integrated mechanisms.
3Reliability
If technicians tighten the sensor connection, then the acoustic pathway improves, but the sensor may be damaged by over-tightening
Solution Approach 1:
The system provides tactile feedback through the latch mechanism that engages with the track at a predetermined position, indicating when the sensor is properly secured. This mechanical feedback ensures consistent, appropriate tightening force is applied without requiring technician judgment or risk of over-tightening.
Solution Approach 2:
The set screw automatically engages with the sensor housing and tightens it to the correct degree through its mechanical interaction with the latch and track system. The design self-regulates the tightening force, eliminating the need for technician skill or judgment to achieve proper sensor securement.
4Adaptability or versatility
If sensors are installed in dirty, wet, below ground and/or awkwardly confined areas, then the application scope increases, but the installation difficulty increases requiring special tools and multiple technicians
Solution Approach 1:
The mounting system is divided into separate, manageable components that can be handled and assembled in confined spaces. The clamp, sensor housing, and fastening mechanism are independent elements that require minimal manipulation and no special tools, making installation feasible in awkward environments.
Solution Approach 2:
The self-adjusting mechanical fastening system requires no special tools or multiple technicians to operate. The set screw and latch mechanism automatically secure the sensor in place through simple manual operation, enabling single-technician installation even in difficult-to-reach locations.
Data Source
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AI summary
A sensor unit to detect fluid movement and/or leakage from a pipe may be attached to a mounting device that is attached to a pipe by a clamp. The mounting device may be configured to transmit vibrations from the pipe and clamp to the sensor. The sensor unit may be attached to the mount in a manner that may be performed rapidly and without tools, and which results in a connection that is not so tight as to damage the sensor, or so loose as to provide inadequate support. The sensor may be attached by connecting at least a portion of the sensor to at least a portion of the mount, using rotation of a key in a track and a latch to securely hold the sensor in the mounting device.