Flexible Sensor Mounting Kit for Uneven Surfaces
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Solution Overview
Problem
Current solutions for mounting sensors on industrial equipment without drilling holes or damaging the surface are inadequate, particularly for uneven or non-metallic surfaces, as they often require custom designs, glue, or magnetic attachments that may not be suitable for all surfaces.
Innovation Solution
A flexible device mounting kit with a scaffolding assembly and teeth that adjust to uneven surfaces, allowing a gluing compound to be filled to create a secure cavity for attaching a sensor mount, which can be detached once solidified, enabling secure attachment of devices to arbitrary surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a custom mount is designed and made to attach to a particular surface, then the sensor can be securely attached, but the design process becomes labor intensive and may not be possible on short notice
Solution Approach 1:
The patent applies universality by creating a standardized scaffolding assembly with guide and teeth that can be used across multiple surfaces and applications. Instead of designing custom mounts for each specific surface, the same modular scaffolding system adapts to different surfaces through its adjustable teeth mechanism, eliminating the need for labor-intensive custom design while maintaining secure attachment.
2Ease of manufacture
If glue is used to attach sensor mounts to a surface, then attachment is simple, but the bond may not be strong enough to withstand the weight of the sensor for extended periods, especially on uneven surfaces
Solution Approach 1:
The patent applies preliminary action by using the scaffolding assembly to pre-form a cavity and prepare the mounting location before applying the gluing compound. The teeth of the scaffolding create a structured cavity that contains and supports the glue, ensuring proper distribution and bonding surface area before the sensor mount is attached, thereby enhancing bond strength while maintaining ease of application.
3Ease of manufacture
If a magnetic sensor mount is used to attach to a metal surface, then attachment is easy, but it only works on metal or magnetic surfaces and requires a reasonably flat surface
Solution Approach 1:
The patent applies universality by creating a scaffolding assembly that can attach to various surface types (metal, plastic, aluminum, stainless steel, and uneven surfaces) through its mechanical teeth structure that conforms to the surface geometry. This universal approach replaces magnetic mounts that are limited to specific surface types, allowing easy attachment across diverse industrial equipment surfaces.
4Reliability
If drilling holes is used to mount a sensor, then secure attachment is achieved, but it may impair structural integrity, inhibit other functionality, void warranties, or have otherwise undesirable effects
Solution Approach 1:
The patent applies the extraction principle by removing the need for drilling holes or removing material from the surface. Instead of creating permanent openings in the equipment surface, the scaffolding assembly with teeth provides a non-invasive attachment method that secures the sensor mount through mechanical interlocking and gluing compound without compromising structural integrity or voiding warranties.
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 kit provides a secure and versatile method to attach sensors or devices to any surface, including uneven ones, without damaging the equipment, ensuring a strong bond and preventing device detachment, thus addressing the limitations of existing mounting solutions.
Implementation Method 1
a gluing compound that attaches to one or more portions of the uneven surface forming part of the cavity after being filled into the cavity
Data Source
AI summary
A flexible device mounting kit allows to securely attach a sensor or another device to an arbitrary surface, including a surface that is very uneven. The kit includes a scaffolding assembly which includes a scaffolding guide and scaffolding teeth attached to the guide in a way that allows some of the teeth to move relative to the guide when the bottom of the teeth is pressed against uneven surface. When the assembly is pressed against the surface, the positions of the teeth adjust, forming, together with the surface, a cavity into which a gluing compound can be filled. A device mount to which a sensor (or another device) can be attached is pressed into the gluing compound before the gluing compound solidifies. As the gluing compound securely connects the sensor mount to the surface, the device can be securely placed within the mount regardless of how uneven the surface is.