Sensor-Integrated Hydraulic Connector for Connection Verification
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Solution Overview
Problem
Existing quick connectors for hydraulic circuits lack direct monitoring capabilities for key parameters, making it difficult to verify correct connection and potentially leading to improper or accidental disconnections, which can result in equipment damage due to uncontrolled fluid pressure and temperature.
Innovation Solution
Equipping the female and male couplings with detection sensors that communicate wirelessly with a control unit to monitor parameters such as fluid flow, pressure, and temperature, allowing for real-time verification of correct connection and generating alerts for parameter deviations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If quick connectors are used for hydraulic circuits without detection sensors, then the device complexity is low and ease of manufacture is high, but the reliability is reduced due to inability to detect connection status and parameter anomalies
Solution Approach 1:
The detection sensor is integrated within the male coupling assembly, nested inside the connector structure. The sensor housing is positioned within the male coupling body, allowing the sensor to be housed inside the connector without requiring separate external mounting structures, thus improving reliability while minimizing additional complexity
Solution Approach 2:
The detection sensor automatically monitors connection status and hydraulic parameters without requiring external intervention. The sensor system self-activates upon coupling connection, continuously monitoring parameters such as fluid flow, pressure, and temperature, and automatically generating alerts when anomalies are detected, improving reliability without proportionally increasing operational complexity
2Reliability
If detection sensors are integrated into the connector, then the reliability and monitoring capability are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The connector system is divided into distinct functional modules: the male coupling assembly containing the sensor, the female coupling assembly, and the sensor housing as a separate integratable component. This segmentation allows sensors to be pre-assembled and tested independently before integration into the final connector assembly, simplifying manufacturing and quality control processes while maintaining reliability
Solution Approach 2:
The detection sensor serves multiple functions simultaneously: detecting connection status, monitoring fluid flow, measuring pressure, and detecting temperature. This multi-functionality reduces the need for separate sensors for each parameter, thereby improving reliability through comprehensive monitoring while minimizing the increase in device complexity and manufacturing cost
3Reliability
If direct monitoring of hydraulic parameters is implemented, then the reliability and safety are improved, but the device complexity and energy consumption increase
Solution Approach 1:
The detection sensor operates by detecting parameter changes periodically or event-driven rather than continuous high-power operation. The sensor monitors hydraulic parameters and activates alert mechanisms only when parameter thresholds are exceeded or connection status changes, improving reliability through continuous monitoring capability while minimizing energy consumption by keeping the system in a low-power state during normal operation
Data Source
AI summary
A hydraulic connector for hydraulic circuits includes a female coupling and a male coupling which are configured to directly couple with and decouple from each other. The female and male couplings do not include inner spaces to accommodate a first sensor. A mutual connection of the female and male couplings facilitates flow of a fluid between the female and male couplings. At least either the male or female coupling includes a first hollow element which is applied directly to an external surface of the male or female coupling to define an inner space. Either the male or female coupling includes the first sensor positioned in the inner space formed by the first hollow element. The first sensor is configured to detect and transmit electronic signals corresponding to working and/or operating parameters and/or values of the connector to a receiver.