Fluid Pipe Detector with Segmented Click Mechanism
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Solution Overview
Problem
Existing fluid pipe detectors require complex shape-processing and high manufacturing costs due to intricate click mechanisms, which also result in large size and potential malfunctions, failing to meet demands for downsizing and multifunctionality.
Innovation Solution
A compact detector design featuring a joint-mounted sensor case with a rotatable holder and cover, utilizing an annular recess and lug mechanism with a resilient member for angle adjustment, eliminating the need for dedicated jigs and tools, and integrating locking components for secure attachment and reduced size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a click mechanism with V-shaped grooves and a ring-shaped leaf spring is used for angle adjustment, then the display portion can be held at predetermined angles, but the manufacturing cost increases due to complicated shape-processing
Solution Approach 1:
The click mechanism is divided into two functional parts: V-shaped grooves provided on the rotary member for angle positioning, and a separate resilient member (such as a pin with spring) that engages with these grooves. This segmentation allows each component to be manufactured independently with simpler processing, reducing overall manufacturing complexity and cost while maintaining the angle holding function.
Solution Approach 2:
The complex ring-shaped leaf spring with V-shaped tongue is extracted and replaced with a simpler resilient member (pin with spring or elastic material) that engages with pre-formed V-shaped grooves. This extraction eliminates the need for complicated shape-processing of a single integrated component, reducing manufacturing cost while preserving the click mechanism's angle adjustment capability.
2Ease of operation
If a ring-shaped leaf spring with V-shaped tongue is used for angle adjustment, then the display portion can be held at predetermined angles, but dedicated jigs are necessary increasing manufacturing steps
Solution Approach 1:
The angle adjustment mechanism is segmented into a rotary member with V-shaped grooves and a separate resilient member. This segmentation allows the V-shaped grooves to be formed by simple machining or molding on the rotary member, while the resilient member can be independently manufactured and assembled, eliminating the need for dedicated crimping jigs and reducing manufacturing steps.
Solution Approach 2:
The resilient member (pin with spring or elastic material) is designed to be self-assembling into the V-shaped grooves through elastic deformation during assembly, rather than requiring external crimping tools or dedicated jigs. This self-service characteristic simplifies the manufacturing process and increases productivity by eliminating specialized tooling requirements.
3Ease of operation
If a ring-shaped leaf spring is crimped and fixed to hold the display portion at angles, then angle adjustment is achieved, but uneven crimping may impair the rotation feel
Solution Approach 1:
The click mechanism is segmented so that the V-shaped grooves are formed on the rotary member itself, while the resilient member (pin with spring) is a separate component that engages with these grooves. This segmentation eliminates the crimping process entirely, as the resilient member simply snaps into the pre-formed grooves, ensuring consistent rotation feel without uneven crimping.
Solution Approach 2:
The resilient member is designed as a simple, inexpensive component (such as an elastic pin or spring-loaded pin) that can be easily manufactured and replaced if needed. This approach replaces the complex, difficult-to-manufacture ring-shaped leaf spring, eliminating crimping operations and ensuring consistent rotation feel through simple snap-fit engagement.
4Reliability
If a long tongue is provided on the leaf spring to ensure resilience, then the spring function is maintained, but the engagement portion and hollow portion have to be large increasing space
Solution Approach 1:
The angle adjustment mechanism is segmented into a rotary member with V-shaped grooves and a separate resilient member (pin with spring). The resilient function is concentrated in the spring component, which can be compact, while the engagement geometry is provided by the V-shaped grooves on the rotary member. This segmentation allows for a compact overall design that maintains spring resilience without requiring large engagement portions or hollow spaces.
Solution Approach 2:
Instead of extending the resilient member (tongue) in one dimension to ensure spring function, the solution uses a pin with spring configuration where the resilient function is achieved in a different dimensional arrangement. The spring can be coiled or folded, providing the necessary resilience in a compact volume, while the V-shaped grooves provide the engagement geometry, significantly reducing the space required for the engagement portion and hollow portion.
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 solution allows for easy angle adjustment of the display with a click feel, prevents malfunctions, reduces manufacturing costs, and achieves a compact, space-saving design while ensuring secure attachment and reduced component complexity.
Implementation Method 1
a resilient member having a projection projecting radially outward is provided on the first lug
Data Source
AI summary
A detector (10) includes: a joint (20) mounted on a fluid pipe; a case (30) mounted on the joint (20) to house a sensor (60); a holder (40) attached to the case (30) and housing a circuit board (70); and a cover (50) attached to the holder (40) and integrated with a light-shielding plate (53). An annular first lug (421), a leaf spring (422) having a projection (423) and a rotation restrainer which projects further from the first lug (421) along an inner circumferential side thereof are integrally formed on the holder (40). An annular first recess (32) to be engaged with the first lug (421) is formed on the case (30). A groove (33) is formed on an inner surface of the first recess. An annular second recess (34) is provided on an inner circumferential side of the first recess (32). A riser portion (35) is provided to a bottom surface thereof.