Multi-directional Motion Monitoring for Electrical Connector Wear
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Solution Overview
Problem
Current electrical connectors lack effective monitoring for vibration-induced motion, which can lead to performance degradation and potential failure due to wear on electrode coatings, especially in environments prone to shock or vibration.
Innovation Solution
A system comprising a connector receptacle, a plug connector, a sensor assembly, and a control system that senses multi-directional motion between the plug and receptacle electrodes, generating data to identify potential wear by comparing motion to a calibrated threshold, thereby facilitating proactive maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical connectors are used in environments prone to shock or vibration, then the connectors must operate in harsh conditions, but the electrode coatings experience wear leading to performance degradation and potential failure
Solution Approach 1:
The system performs preliminary monitoring of connector motion and compares it against calibrated threshold profiles that represent acceptable wear levels. By detecting excessive motion before it causes actual electrode wear, the system enables proactive maintenance or replacement, preventing performance degradation and failure before they occur.
Solution Approach 2:
The system continuously monitors connector motion using sensors and provides feedback about the magnitude and direction of movement. This feedback is compared against calibrated thresholds to determine if wear is occurring, enabling real-time assessment of connector health and facilitating timely maintenance decisions.
2Measurement precision
If sensor assemblies are added to monitor connector motion, then wear detection capability is improved, but device complexity increases
Solution Approach 1:
The sensor assembly and control system are designed to monitor multiple parameters (magnitude and direction of motion) simultaneously using a unified multi-directional sensing approach. This multi-functional system can detect various types of motion (vibration, shock, insertion/removal) with a single integrated setup, reducing overall system complexity compared to multiple separate monitoring systems.
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 continuous monitoring of connector wear, reducing the risk of performance degradation and failure by detecting excessive motion-induced wear, allowing for timely maintenance and ensuring reliable electrical connections.
Implementation Method 1
The sensor assembly is configured to sense in multiple directions motion of the plug connector relative to the connector receptacle when the plug connector is operatively plugged to the connector receptacle
Data Source
AI summary
Multi-directional monitoring of connector motion is provided to facilitate identifying potential wear of one or more connector electrodes. A sensor assembly is configured to sense in multiple directions motion of a plug connector relative to a connector receptacle when the plug connector is operatively plugged to the connector receptacle, and to generate sensor data based on sensed motion of the plug connector relative to the connector receptacle. A control system is provided to monitor, based on the sensor data, motion of the plug connector relative to the connector receptacle to facilitate identifying potential wear of one or more electrodes of the plug electrode(s) and the receptacle electrode(s) due to the motion.