Interconnectable Sensor System Quick-Change Mechanism
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Solution Overview
Problem
Conventional sensors require breaching fluid containers to install or remove, leading to reduced efficiency and potential contamination due to flow shutdowns.
Innovation Solution
A two-part interconnectable sensor system with a quick change connection and disconnection system, featuring a first connection component with a locking pin, locating pin, and spring-loaded electrical contact, and a second connection component with an alignment feature and locking feature, allowing for secure lateral and rotational positioning without breaching the container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sensors are installed by breaching the fluid container, then the sensor can be securely positioned in the fluid flow, but the fluid flow must be shut down and the container integrity is compromised
Solution Approach 1:
The sensor system is divided into separate components: a sensor assembly and a connection assembly. The connection assembly includes a coupling that interfaces with the sensor assembly through a quick-connect mechanism, allowing the sensor to be installed or removed without breaching the fluid container. This segmentation enables the sensor portion to remain outside the fluid stream while maintaining functional connection.
Solution Approach 2:
A connection assembly acts as an intermediary between the sensor assembly and the fluid container. The connection assembly includes a coupling with electrical contacts that transmit signals and power to the sensor assembly without requiring direct physical penetration of the fluid container, thus maintaining container integrity while enabling sensor functionality.
2Reliability
If the fluid container is breached for sensor installation, then the sensor can be positioned in the fluid flow, but contaminants can enter the fluid
Solution Approach 1:
The sensor system separates the sensing function from the fluid container structure. The sensor assembly contains the sensing elements while the connection assembly provides the interface to the fluid container through a sealed coupling mechanism, eliminating the need to breach the container and preventing contaminant entry.
3Productivity
If a quick change connection system is implemented, then sensor installation and removal can be done without shutting down fluid flow, but the connection mechanism becomes more complex
Solution Approach 1:
The connection assembly incorporates a dynamic quick-connect mechanism with movable components including a coupling with electrical contacts that can engage and disengage rapidly. The coupling includes spring-loaded electrical contacts that automatically make or break electrical connections during the quick-connect operation, enabling fast sensor replacement without manual wiring operations.
4Reliability
If locking and alignment features are added to maintain lateral and rotational position, then the connection stability is improved, but the connection component complexity increases
Solution Approach 1:
The coupling incorporates asymmetric alignment features including a keyed interface or cam mechanism that provides unique lateral and rotational positioning. The asymmetry ensures that the coupling can only engage in one specific orientation, automatically aligning the electrical contacts and mechanical locking surfaces while preventing misalignment or incorrect installation.
Data Source
AI summary
A sensor interconnect system is disclosed. The sensor interconnect system comprises a first connection component comprising a locking pin, a locating pin and a spring loaded electrical contact comprising at least one contact pin and a second connection component comprising an alignment feature, a locking feature, and a second electrical contact. The second connection component is coupled to a sensor located in a contained fluid sensing area. The locking pin interacts with the locking feature to maintain a lateral position of the first connection component relative to the second connection component and the locating pin interacts with the alignment feature to maintain a rotational position of the first connection component relative to the second connection component. The at least one contact pin of the spring loaded electrical contact is in electrical communication with the second electrical contact, when the system is assembled.