Foot Switch Housing Self-Test for Leak Detection
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Solution Overview
Problem
Existing methods for checking the tightness of switch housings, particularly in the medical field, are inadequate as they often require external testing equipment, which is inconvenient and may miss leaks that occur during operation. Additionally, these methods struggle to accurately detect leaks under varying ambient conditions.
Innovation Solution
A method that evaluates pressure, temperature, and humidity changes within the housing using internal sensors. By inducing a pressure change and measuring the resulting pressure curve, the method can reliably detect leaks while accounting for temperature fluctuations and humidity levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If external testing equipment is used to check housing tightness, then the housing can be tested for leaks, but the switch operation is interrupted and testing work increases
Solution Approach 1:
The switch housing performs self-testing by utilizing its own internal volume and actuating element to create pressure changes. The evaluation unit monitors pressure variations within the housing during normal operation, eliminating the need for external testing equipment and interrupting switch operation.
Solution Approach 2:
The housing serves multiple functions: it protects the switching element, contains the actuating element, and simultaneously serves as the testing chamber for leak detection. The internal volume of the housing is used both for its operational purpose and for pressure-based leak testing.
2Reliability
If external testing equipment is used, then the housing can be pressurized from the outside, but leaks during operation remain undetected
Solution Approach 1:
The leak testing is performed continuously or periodically during normal switch operation rather than requiring separate external testing sessions. The evaluation unit continuously monitors pressure changes within the housing, enabling immediate detection of leaks as they occur during operational use.
Solution Approach 2:
The evaluation unit receives feedback from pressure sensors monitoring the internal pressure of the housing and immediately detects deviations that indicate leaks. This closed-loop feedback system enables real-time leak detection during operation, eliminating delays between leak occurrence and detection.
3Reliability
If the housing is opened to detect moisture ingress, then moisture can be detected, but the housing seal is compromised
Solution Approach 1:
The patent replaces mechanical opening of the housing with an electronic sensing system. Pressure sensors and evaluation units monitor internal pressure changes and humidity levels through the intact housing structure, eliminating the need to open or compromise the seal to detect moisture ingress.
4Ease of operation
If pressure change method is used for leak testing, then spontaneous testing is possible, but temperature fluctuations cause incorrect results
Solution Approach 1:
The system monitors multiple parameters simultaneously including pressure, temperature, and humidity. By tracking temperature changes alongside pressure changes, the evaluation unit can distinguish between pressure variations caused by leaks versus those caused by temperature fluctuations, maintaining measurement precision while preserving spontaneous testing capability.
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 allows for spontaneous and reliable leak detection in switch housings, even under varying ambient conditions, and can be performed regularly without disrupting the switch's operation.
Implementation Method 1
at least one pressure sensor for measuring a pressure in the internal volume
Implementation Method 2
a temperature sensor as well as an evaluation unit, wherein the evaluation unit is set up to carry out a method according to the invention
Implementation Method 3
the actuation of which changes the inner volume of the housing
Data Source
AI summary
A housing with an internal volume is leak tested by changing an internal pressure in the internal volume of the housing and determining a first internal pressure and a first temperature. A second internal pressure and a second temperature are determined. It is then determined whether an absolute value of a difference between the second internal pressure and the first internal pressure, considering a difference between the first and second temperatures, is above a threshold value. A signal representing the result of the previous step is output.