Modular Digital FRL Connector for Secure Air and Electrical Coupling
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Solution Overview
Problem
Existing modular digital filter, regulator, and lubricator (FRL) systems lack efficient and easy-to-use connections for both electrical and air-line systems, often leading to accidental disconnections and inadequate monitoring of air quality, which can shorten the lifespan of tools and machines.
Innovation Solution
A modular digital FRL connector and system that incorporates digital, visual, and audible warnings, along with a digital display for monitoring air quality and pressure, and includes modular connectors for quick and secure attachment and detachment of FRL devices, reducing the likelihood of accidental disconnections and providing real-time alerts for maintenance needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional connection methods are used for FRL devices, then the system structure is simple, but accidental disconnections occur and electrical connections require wire pig-tailing which is time-consuming
Solution Approach 1:
The patent combines electrical connections and air line connections into a single integrated connector assembly. The electrical connector and air line connector are merged into one unit that attaches to the FRL device simultaneously, eliminating the need for separate wire pig-tailing and air line connection operations. This merging resolves the contradiction by improving connection efficiency without creating excessive complexity, as the integrated design streamlines the overall attachment process.
Solution Approach 2:
The connector assembly serves multiple functions: it provides both electrical connectivity and pneumatic connectivity through a single attachment operation. The universal design allows one connector to handle both electrical wires and air lines, eliminating the need for separate connection mechanisms. This multi-functionality directly addresses the contradiction by making the connection process easier and faster while the integrated structure manages the complexity internally.
2Ease of repair
If modular FRL devices are used, then maintenance and replacement are easier, but accidental disconnections can occur
Solution Approach 1:
The connector incorporates asymmetric locking features including cam-actuated latches and bayonet-style engagement mechanisms. These asymmetric designs provide distinct engagement and disengagement directions, ensuring that the connection can only be made in the correct orientation and requires deliberate action to disconnect. This resolves the contradiction by providing secure, accident-proof connections while maintaining ease of intentional replacement through the cam-actuated release mechanism.
Solution Approach 2:
The connector includes preliminary locking actions that automatically engage when the connector is attached to the FRL device. The cam-actuated latches and bayonet engagement mechanisms automatically lock into place upon insertion, preventing accidental disconnection before any operational stress is applied. This preliminary securing action ensures reliability while allowing easy intentional removal when maintenance is needed.
3Measurement precision
If digital monitoring is added to FRL systems, then air quality and pressure can be monitored in real-time, but the device complexity increases
Solution Approach 1:
The digital monitoring system is designed to be self-contained within the FRL device, with integrated sensors, displays, and alert mechanisms. The system monitors its own operational parameters (air quality, pressure, moisture content) and provides self-diagnosis capabilities through visual and audible alerts. This self-service approach resolves the contradiction by providing precise monitoring capabilities while managing complexity through integration and automation, eliminating the need for external monitoring equipment.
Solution Approach 2:
The monitoring functions are merged into the existing FRL device structure rather than being added as separate external systems. Sensors for air quality, pressure, and moisture monitoring are integrated within the FRL housing, and the display and alert mechanisms are combined with the existing device interface. This merging resolves the contradiction by providing comprehensive monitoring capabilities while minimizing additional complexity through integrated design.
Data Source
AI summary
A modular digital filter, regulator and lubricator (FRL) connector and system are provided. The modular digital filter, regulator and lubricator connector and system are especially suitable for use in improving compressed air quality so as to extend the life of tools and machines which are connected to the FRL devices. The connector device and system allows for a quick and efficient connection with respect to both electronics and air lines and reduces problems that arise from wire pig-tailing or accidental disconnection of the FRL. The device and system may have digital, visual and audible warnings with respect to the quality of air passing through the system and to the tools and machines.