Connector Pin Current Monitoring for Corrosion Isolation
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Solution Overview
Problem
Electrical contacts in devices exposed to conductive/corrosive fluids, such as seawater and chemicals, suffer from degradation due to electrolysis and galvanic corrosion, with existing passive methods like sealing introducing additional paths for fluid entry and manual disablement being ineffective if not properly executed.
Innovation Solution
A system comprising a non-ferrous sensor body with insert members and a pin monitoring section that operates in three modes to detect current flow, sense the presence of a fastener, and compare current values to predetermined ranges, automatically isolating power to affected pins to prevent corrosion, using a contactless Hall effect sensor or similar technology to avoid introducing contamination paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If passive sealing methods (covers, fasteners, seal members, sealants) are added to protect electrical connectors, then corrosion protection is improved, but device complexity increases and additional paths for conductive fluid entry are introduced
Solution Approach 1:
The patent extracts the harmful fasteners and seal members from the connector structure by using a bayonet-style coupling mechanism that achieves sealing through the interface between mating connectors themselves, eliminating the need for additional sealing components that would increase complexity
Solution Approach 2:
The sealing function is merged into the connector interface design itself, where the bayonet coupling mechanism integrates the sealing action into the basic connection operation, so that sealing is achieved through the inherent geometry of the mating connectors rather than separate sealing components
2Reliability
If manual disablement of electrical interface is performed to prevent corrosion, then corrosion protection is improved, but reliability decreases due to operator error
Solution Approach 1:
The system performs self-service by automatically detecting corrosion through sensors and triggering protective actions without requiring manual intervention, ensuring consistent corrosion protection regardless of operator presence or competence
Solution Approach 2:
The patent implements feedback through sensors that continuously monitor the electrical interface for signs of corrosion, with the system responding automatically to detected conditions, creating a closed-loop protection mechanism that adapts to actual corrosion risk
3Productivity
If electrical connectors remain energized during operation, then productivity is improved, but corrosion risk increases due to electrolysis and galvanic corrosion
Solution Approach 1:
The system dynamically adjusts the operational state of electrical connectors based on real-time corrosion risk assessment, transitioning between energized and de-energized states as needed to balance productivity with corrosion prevention
Solution Approach 2:
The patent applies preliminary action by implementing sensors and monitoring systems that detect early signs of corrosion before significant damage occurs, allowing preventive measures to be taken while maintaining productivity
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
The system effectively detects and mitigates corrosion by automatically isolating power to affected pins, reducing the risk of fluid entry and maintaining electrical integrity without manual intervention, thus protecting electrical components from conductive/corrosive environments.
Implementation Method 1
A sensor body created of a non-ferrous material connected to the component includes... A second insert member defines a sensor to sense proximal presence of a fastener
Data Source
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AI summary
A monitoring system for connector pins exposed to conductive/corrosive fluids and/or corrosive environments includes a first sensing portion having a pin monitoring section configured to measure a pin current flow of at least one conductor pin, and transfer a first signal. A second sensing portion produces a second signal indicating by a contactless determination the presence of a fastener providing physical connection between an interface member and a component. A decision logic device receives the first and second signals, compares the pin current flow to a predetermined range of values, and isolates electrical power to the conductor pin when the first signal indicates the pin current flow is outside the predetermined range of values. A sensor body created of a non-ferrous material and connected to the component includes a first insert member having the conductor pin and a second insert member defining a sensor sensing proximal presence of the fastener.