Gauge Sensor Battery Module for Rapid Explosion-Proof Replacement
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Solution Overview
Problem
Existing sensor devices for gauges in explosion-proof areas require complex mechanisms for battery replacement, leading to increased costs and longer replacement times, and often necessitate multiple power cables and connectors, which are costly and cumbersome.
Innovation Solution
A sensor device with a stackable body and battery unit configuration, allowing for easy assembly and disassembly without screws, and meeting explosion-proof specifications, enabling rapid battery replacement without removing the device from the hazardous area.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a swingable member mechanism is used for battery replacement, then battery replacement is enabled, but device complexity increases and replacement speed decreases
Solution Approach 1:
The sensor device is divided into two independent explosion-proof modules: the body (containing sensor circuit) and the battery unit (containing battery). This segmentation allows the battery unit to be replaced independently without affecting the body, eliminating the need for complex swingable members while enabling rapid battery replacement in explosion-proof areas.
Solution Approach 2:
The battery unit is extracted as a separate replaceable component from the sensor device body. The battery casing includes a battery container and lid that can be opened to access and replace batteries, while the body remains attached to the gauge. This extraction eliminates the need for complex retention mechanisms.
2Reliability
If multiple power cables and connectors are used, then power supply is ensured, but cost increases and installation becomes cumbersome
Solution Approach 1:
The power supply function is merged into the battery unit, which contains the battery and provides power to the sensor circuit through internal electrical connection. This eliminates the need for external power cables and connectors, reducing installation complexity while ensuring reliable power supply in explosion-proof areas.
3Reliability
If a swingable member is used for battery retention, then battery containment is achieved, but manufacturing cost increases
Solution Approach 1:
The battery unit is designed as a disposable or easily replaceable component with a simple structure. The battery casing includes a battery container and lid with basic retention features, eliminating the need for expensive swingable members. This simple design reduces manufacturing cost while maintaining adequate battery containment.
Data Source
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AI summary
A sensor device (D1) is attachable for use to a gauge (G1) and configured to obtain a measurement from the gauge (G1) contactlessly, the gauge (G1) including: a dial plate (G16) provided with a scale mark (G161); a needle (G14) rotatable over the dial plate (G16); and a shaft configured to rotate the needle (G14). The sensor device (D1) includes a body (M1) and a battery unit (B1). The body (M1) includes a body casing (1) containing a sensor circuit configured to obtain the measurement. The battery unit (B1) includes a battery casing (5) containing at least one battery cell configured to supply electric power to the sensor circuit. The body (M1) and the battery unit (B1) are configured to be assembled to each other as a result of the body casing (1) and the battery casing (5) being stacked on top of each other.