Adapter Plug Assembly for Tolerant Valve Module Mounting
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Solution Overview
Problem
Existing electronics modules for electrically actuated valves face issues with ease of mounting, risk of line crushing, electrostatic discharges, and soiling due to large openings, which can lead to valve failure and leaks.
Innovation Solution
An adapter plug with actuator-side and electronics-side receptacles, allowing direct contacting of an integrated electronics module with a hydraulic unit, featuring tolerance and play in multiple directions for positional compensation, and a securing mechanism to prevent detachment, along with an elastic element for vibration damping and insulation to prevent contact between conductive components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mounting pliers through blade receptacles are used to connect electronics module with hydraulic unit, then electrical connection is established, but line crushing occurs when electronics housing is placed and fixed
Solution Approach 1:
The adapter plug serves as an intermediary component between the actuator and the electronics module. It provides a robust mounting interface that eliminates the need for mounting pliers to pass through the electronics housing, thereby preventing line crushing while ensuring reliable electrical connections. The adapter plug's main body is designed to be received by the actuator, and its contact elements establish electrical connections without requiring the electronics housing to be compressed.
2Ease of operation
If large openings are provided on electronics housing for line access, then ease of mounting is improved, but soiling by electrically conductive particles and electrostatic discharges occur
Solution Approach 1:
The adapter plug extracts the electrical connection function from the electronics housing structure. By providing contact elements on the adapter plug itself that can be directly connected to actuator contacts, the need for large openings in the electronics housing is eliminated. This extraction of the connection function to a separate component prevents soiling and electrostatic discharge risks while maintaining ease of connection.
3Ease of operation
If adapter plug is inserted with tolerance and play for positional compensation, then ease of mounting by untrained personnel is improved, but adapter plug stability is worsened
Solution Approach 1:
The adapter plug design incorporates dynamic characteristics by allowing controlled movement and adjustment within the actuator recess. The contact elements are designed to accommodate positional deviations through elastic deformation and self-adjustment mechanisms, enabling untrained personnel to easily mount the device while maintaining stable electrical connections. The system adapts to positional variations rather than requiring precise alignment.
Data Source
AI summary
An adapter plug and an electronics housing includes an adapter plug of this kind, and a valve comprising an electronics housing of this kind. The valve has at least one electric actuator. The adapter plug has at least one receptacle for an actuator-side electrical contact element and a receptacle for an electronics-side electrical contact element. The two receptacles are electrically connected to one another. A main body of the adapter plug is designed for insertion into a recess of a wall portion of the electronics housing, which wall portion faces the actuator. The main body can be fastened to an edge of the recess with tolerance or play so as to be able to compensate for positional deviations of the at least one actuator relative to the electronics housing.