HVAC Sensor Mounting Clamp With Interlocking Pockets
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional sensor mounting systems in HVAC systems fail to securely lock temperature sensors in place, leading to inaccurate readings and inefficiencies such as high compressor head temperatures, increased power consumption, and refrigerant leakage.
Innovation Solution
A sensor mounting clamp with interlocking pockets and a motion-constraining flange that securely locks the sensor in place using retention pieces like cotter pins or screws, ensuring accurate temperature measurements by preventing longitudinal and rotational movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sensor mounting systems are used, then the device complexity is low, but the sensor stability and measurement precision deteriorate due to inadequate locking
Solution Approach 1:
The clamp structure is divided into multiple functional segments: a clamp body for circumferential clamping, interlocking pockets for longitudinal positioning, and a flange with pockets for rotational constraint. This segmentation allows each component to perform its specific function effectively, achieving stable sensor mounting without excessive overall complexity.
Solution Approach 2:
The clamp design incorporates nested functional elements where interlocking pockets are integrated into the clamp body, and additional pockets are integrated into the flange structure. This nesting approach maximizes functionality within a compact form factor, providing multiple constraints without proportionally increasing complexity.
2Measurement precision
If conventional sensor mounting systems are used, then the manufacturing process is simple, but the measurement precision deteriorates due to sensor movement
Solution Approach 1:
The clamp design applies different constraint mechanisms at different locations: the clamp body provides circumferential clamping force, the first set of pockets provides longitudinal positioning, and the flange with second set of pockets provides rotational constraint. This localized quality approach ensures precise sensor positioning in all degrees of freedom without requiring complex mechanisms throughout the entire structure.
3Reliability
If a secure locking mechanism is implemented, then the sensor stability improves, but the ease of operation deteriorates due to complex installation
Solution Approach 1:
The interlocking pockets are designed to automatically engage and constrain the sensor in the longitudinal direction without requiring additional fastening operations. The flange structure with integrated pockets provides self-constraining rotational positioning, reducing the number of manual steps required during installation while maintaining secure locking.
Data Source
AI summary
The embodiments described herein include sensor mounting clamps configured to lock a sensor, such as a temperature sensor, in place relative to a structure, such as a pipe or tube, of a heating, ventilating, and/or air conditioning (HVAC) unit. More specifically, the sensor mounting clamps described herein include sensor mounting portions configured to receive a sensor, and to hold the sensor in place relative to a structure of an HVAC unit. In addition, the sensor mounting clamps described herein include locking mechanisms having interlocking pockets configured to lock the sensor mounting clamps in place around a structure of an HVAC unit. For example, the sensor mounting clamps described herein may include interlocking pockets having interior passages configured to receive a retention piece, such as a cotter pin, cylindrical pin, or screw, to lock the interlocking pockets in place relative to each other, or may include interlocking pockets configured to directly engage with each other. In addition, the sensor mounting clamps described herein may include a flange configured to constrain longitudinal motion of a sensor.