Hygienic Sensor Unit with Self-Aligning Wall Connection
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Solution Overview
Problem
Existing sensor units for hygiene-critical areas do not comply with hygiene regulations, complicating installation and alignment, are costly, and require extensive cleaning, posing a risk of damage.
Innovation Solution
A sensor unit with a hygienic cover and connecting device featuring an external thread and internal thread for a force-fitting connection, allowing magnetic or inductive data acquisition, and a sealing mechanism to ensure cleanliness and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensor units are installed in a closed wall separated from the hygiene-critical area, then hygiene compliance is improved, but installation complexity and alignment difficulty increase
Solution Approach 1:
The sensor unit is divided into two distinct parts: a hygiene-compliant passage end that penetrates the wall into the hygiene-critical area, and a non-hygienic sensor housing that remains outside. This segmentation allows each part to fulfill its specific function while maintaining hygiene standards and simplifying installation.
Solution Approach 2:
A connection piece serves as an intermediary element between the passage end and the sensor housing. This mediator enables flexible alignment and simplified installation by decoupling the positioning requirements of the hygiene-critical passage end from the sensor housing, while maintaining signal transmission.
2Ease of operation
If sensor units are designed to be blindly installed, then installation simplicity is improved, but not all sensor units can be blindly installed and alignment becomes problematic
Solution Approach 1:
The passage end is designed with self-aligning features including a conical insertion end that automatically centers itself in the wall opening during installation, and a connection piece with lateral alignment elements. This self-service mechanism enables blind installation without requiring precise pre-alignment or specialized installation expertise, while maintaining compatibility with various sensor units.
3Reliability
If hygiene-critical components use complex sensor units that comply with hygiene regulations, then hygiene compliance is improved, but manufacturing cost and cleaning complexity increase
Solution Approach 1:
The complex sensor housing is extracted from the hygiene-critical area and placed outside the wall. Only the essential passage end with minimal surface area penetrates into the hygiene zone. This extraction eliminates the need for complex hygiene-certified sensor housings while maintaining compliance, as the simple passage end can be easily cleaned and does not require complex internal components.
Solution Approach 2:
The passage end is designed as a simple, inexpensive component with a smooth conical surface that can be easily cleaned or replaced. Instead of investing in expensive, complex hygiene-certified sensor units, the solution uses a simple disposable or easily replaceable passage end that meets hygiene requirements through its simplicity and ease of cleaning.
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a sensor unit (1) for a through connection with a system wall (2) of a hygiene-critical technical system, comprising a passage end (4) located within a hygiene area (3) of the technical system in the case of use, further comprising a hygiene cover (5) for the passage end (4) and a connection device (6) for a force-fit connection between hygiene cover (5) and system wall (2), in order to propose a simple, cost-effective and modular sensor unit for a hygiene-critical technical system.