Intercom Mounting Substructure With Precise Connector Alignment
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Solution Overview
Problem
The maintenance, repair, and replacement of intercom units on naval vessels require significant effort, including opening the housing to disconnect electrical cables, re-measuring electromagnetic shielding, and necessitating the presence of a safety-certified person.
Innovation Solution
A substructure device with a housing that holds the intercom unit, allowing cable routing through a housing cavity, and a placement aid that ensures precise connector alignment without opening the unit, enabling easy replacement and maintenance without re-measuring shielding or requiring a certified person.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the intercom unit is directly mounted on the substrate with internal cable routing, then the electromagnetic shielding is maintained, but the maintenance and replacement require opening the housing and re-measuring shielding
Solution Approach 1:
The system is divided into two independent parts: the intercom unit and the substructure device. The cable routing is segmented to pass through the substructure device rather than the intercom unit housing. This allows the intercom unit to be replaced without opening its housing or disturbing the cable routing, thereby reducing maintenance time while preserving electromagnetic shielding integrity.
Solution Approach 2:
The substructure device acts as an intermediary between the substrate and the intercom unit. It provides the cable routing function externally, mediating the connection between cables and the intercom unit without requiring access to the intercom unit's internal housing. This intermediary structure enables easy unit replacement while maintaining shielding.
2Ease of repair
If the housing is opened to replace components, then repairs can be performed, but the electromagnetic shielding must be re-measured and safety-certified personnel are required
Solution Approach 1:
The cable routing function is extracted from the intercom unit housing and placed in the substructure device. This extraction eliminates the need to open the housing for cable access, simplifying the replacement process to merely detaching the unit from the substructure. The complex steps of opening housing, protecting cables, and re-measuring shielding are eliminated.
Solution Approach 2:
The cable routing is preliminarily arranged through the substructure device before the intercom unit is mounted. The connector is pre-positioned in the substructure device, so when the unit is attached, the electrical connection is automatically established without requiring any housing manipulation or subsequent shielding measurements.
3Ease of operation
If cables are routed through the intercom unit housing, then direct connection is achieved, but the housing must be opened for any cable work
Solution Approach 1:
The substructure device serves as an intermediary for cable routing, positioned between the substrate and the intercom unit. Cables are routed through this intermediary structure, allowing cable connections to be made and maintained without opening the intercom unit housing. The connector in the substructure device provides easy access for cable work while preserving the integrity of the intercom unit.
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
A substructure device for mounting an intercom unit (10) on a substrate, wherein the substructure device is designed as a housing (1) having a fastening side (2) for fastening the housing (1) to the substrate and a holding side (3) for holding the intercom unit (10) on the housing (1), and wherein the substructure device has a placement aid (8, 11, 12) for placing the intercom unit (10) on the holding side (3), wherein a housing cavity (4) is present between the fastening side (2) and the holding side (3), into which at least one line for transmitting signals and/or data and/or power from or to the intercom unit (10) is led from outside the housing (1), wherein the at least one line has a plug connector (5) for connecting to a mating plug connector (6) on the intercom unit (10), wherein an access opening (7) is present on the holding side (3) of the housing (1),through which the housing cavity (4) is accessible, and wherein the intercom unit (10) can be placed on the holding side (3) by means of the placement aid device (8, 11, 12) in such a way that, on the one hand, the plug connector (5) is connected to the mating plug connector (6) with a precise fit and, on the other hand, the access opening (7) is closed.