Tool-Free Bolted Connection Temperature Sensor
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing temperature sensing technologies for bolted connections in electrical equipment require specialized tools and equipment for installation, making them costly and prone to installation errors, and may not effectively detect corrosion or loss of integrity at mechanical junctions.
Innovation Solution
A simple, tool-free temperature sensor with a thermally conductive housing and integrated transducer that can be easily attached to bolted connections on bus bars, using wireless or wireline communication to transmit data without the need for batteries, powered by parasitic energy harvesting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional temperature sensors are installed on power buses, then temperature monitoring capability is improved, but installation complexity and cost increase due to specialized tools and equipment requirements
Solution Approach 1:
The patent replaces traditional mechanical fastening systems with specialized tools with a simple snap-fit or push-on mounting mechanism. The sensor housing includes a mounting structure that mechanically engages with the bus bar connection point without requiring torque tools, drills, or other specialized equipment, thereby maintaining reliable temperature monitoring while eliminating installation complexity
Solution Approach 2:
The sensor incorporates self-aligning and self-securing features that allow it to be installed without external assistance or specialized tools. The mounting mechanism automatically engages with the bus bar structure, and the sensor performs its own temperature sensing and data transmission functions without requiring complex installation procedures
2Reliability
If traditional temperature sensors are used, then temperature detection is achieved, but installation errors increase due to complex installation procedures
Solution Approach 1:
The complex mechanical fastening system is replaced with a simple engagement mechanism that has inherent alignment features. The sensor housing includes guides or positioning elements that ensure correct orientation and placement on the bus bar, eliminating the need for precise manual alignment and reducing installation errors
Solution Approach 2:
The sensor is pre-configured with mounting features and alignment elements during manufacturing. The mounting structure is designed to automatically position the sensor correctly on the bus bar connection point, so that proper alignment and secure attachment are achieved before the actual installation act, preventing installation errors
3Reliability
If specialized installation tools are used, then sensor attachment is secured, but installation cost and time increase
Solution Approach 1:
The patent replaces multi-step mechanical fastening requiring specialized tools with a single-step snap-fit or push-on mounting system. The sensor housing incorporates integrated mounting features that engage with the bus bar structure in one motion, achieving secure attachment without the time-consuming sequence of tool operations
Solution Approach 2:
The sensor performs its own mounting function through self-securing features that automatically engage with the bus bar structure. The mounting mechanism is designed to lock into place through simple user action, eliminating the need for external tools and reducing installation time to a minimum
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables cost-effective, error-minimized installation and real-time temperature monitoring of bolted connections, allowing for early detection of corrosion or integrity loss, thus preventing operational failures and safety hazards.
Implementation Method 1
The housing is formed of a thermally conductive material... The skirt portion of the housing is in thermal contact with the bolted connection... The temperature transducer is in thermal contact with the housing
Implementation Method 2
The data collector may be a parasitically powered device that may provide operating power to the temperature sensor over the sensor wires
Data Source
AI summary
A temperature sensor 31A for bolted connections 8A, includes a thermally conductive housing 30 having a skirt portion 62 with an opening shaped to fit on a portion of a bolted connection of a bus bar. The skirt portion of the housing is configured to be in thermal contact with the bolted connection when the skirt portion is fitted on the bolted connection of the bus bar. The temperature sensor further includes a temperature transducer 70 in thermal contact with the housing. The temperature transducer is configured to sense a temperature of the housing which relates to a temperature of the bolted connection and to output signals to a data collector 1 via wireless or wireline communication.