Automation Field Device Plug Sleeve Welding
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Solution Overview
Problem
Field devices in hygienic processes, such as those in the food industry, face challenges in welding plug connectors to their housings without using a hold-down device, due to the small contour and non-radial weld seam, which complicates the welding process and exposes the connector to dynamics and inert gas streams.
Innovation Solution
A custom-fit plug sleeve is fastened to a retaining means within the field device housing, such as an electronics cup, to maintain its position during welding, allowing for laser access without a hold-down device and protecting the connector from welding system dynamics and inert gas influences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a hold-down device is used to secure the plug sleeve during welding, then the plug sleeve position is stable, but the device complexity increases and the welding installation becomes too large for the small contour
Solution Approach 1:
The plug sleeve is pre-secured to the retaining means (electronics cup) before the welding operation begins. This preliminary fastening ensures the plug sleeve remains in the correct position during welding without requiring external hold-down devices, thereby simplifying the welding installation while maintaining positioning stability.
2Manufacturing precision
If a hold-down device is used to secure the plug sleeve, then positioning is maintained, but the interference contour becomes too large for the small welding area
Solution Approach 1:
The plug sleeve is nested within the housing opening and secured to the retaining means (electronics cup) that is already positioned inside the housing. This nested arrangement allows the plug sleeve to be held in position during welding without requiring external hold-down devices that would increase the contour size, thus maintaining a compact welding installation suitable for small contours.
3Device complexity
If the plug sleeve is not secured during welding, then the welding installation remains simple, but the plug connector is affected by welding dynamics and inert gas streams
Solution Approach 1:
The retaining means (electronics cup) acts as an intermediary between the plug sleeve and the housing. It provides a secure mounting point inside the housing for the plug sleeve, protecting it from welding dynamics and inert gas streams during the welding operation, while keeping the welding installation simple without external hold-down devices.
4Ease of operation
If the plug sleeve is fastened internally to a retaining means, then blind installation becomes possible and laser access is improved, but the internal structure becomes more complex
Solution Approach 1:
The retaining means (electronics cup) serves multiple functions: it holds the electronic circuit components, provides a mounting point for the plug sleeve, and acts as a structural support element. By combining these functions into a single component, the internal structure remains relatively simple while enabling blind installation and improving laser access during welding.
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
This method enables secure welding of the plug connector without external hold-down devices, ensuring cleanliness and precision, and allows for blind installation, addressing the limitations of existing welding techniques in hygienic environments.
Implementation Method 1
a plug sleeve (26) being placed over the field contact plug, said plug sleeve being welded onto the field device housing
Data Source
AI summary
An automation field device includes a metallic field device housing enclosing an interior; a sensor element and/or actuator element placed on one side on the field device housing, —for actuating and/or acquiring a process variable; an electronic circuit that is arranged in the interior of the field device housing and is configured to provide and/or process a sensor and/or actuator signal for and/or from the sensor element and/or actuator element, the electronic circuit furthermore having at least one field contact plug for transmitting data and/or energy, the field contact plug being guided outward through an opening in the field device housing, a custom-fit plug sleeve being plugged over the field contact plug, said plug sleeve being welded onto the field device housing and being fastened to a retaining means arranged in the interior.