Magnetic Round Plug Adjustment for Sealed On-Site Parameter Setting
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Solution Overview
Problem
Industrial automation devices often lack a convenient and reliable adjustment mechanism that can withstand high-tightness requirements and is easy to manufacture, as existing solutions are either complex, expensive, or prone to leakage.
Innovation Solution
A round plug with a sleeve-type adjustment element comprising an inner and outer sleeve, a magnet, and a spring wire, which is pre-assembled and securely attached to the housing, allowing for rotatable operation and direct parameterization without external apertures, ensuring high-tightness and ease of manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a pushbutton, magnetic switch or potentiometer is used as an input unit, then the device can be operated directly, but the housing requires additional sealing effort and the device complexity increases
Solution Approach 1:
The adjustment element is nested within the housing without requiring external apertures. The inner sleeve contains the magnet, which is detected by the sensor element inside the housing, creating a nested configuration that eliminates the need for sealing openings while maintaining direct operability.
Solution Approach 2:
The magnet serves as an intermediary between the outer sleeve (operated by user) and the sensor element (inside housing). The magnetic field transmits the rotational position information through the housing wall without requiring physical penetration, thus maintaining sealing integrity while enabling direct operation.
2Ease of operation
If adjustment elements are located directly at the device, then adjustments can be made conveniently on site, but the risk of leakage increases due to required openings in the housing
Solution Approach 1:
The adjustment mechanism is nested within the sealed housing structure. The inner sleeve with magnet is contained within the housing, and the sensor element detects the magnet's position through the housing wall, eliminating the need for apertures that would compromise tightness while allowing on-site adjustments.
Solution Approach 2:
The magnetic field acts as an intermediary that transmits rotational information from the outer sleeve to the sensor element through the sealed housing wall, enabling on-site adjustment convenience without creating leakage paths that would compromise reliability.
3Ease of operation
If a removable switching element is used, then the device can be adjusted, but the switching element can be lost and the device complexity increases
Solution Approach 1:
The adjustment element (outer sleeve with magnet) and the detection system (sensor element) are merged into a single integrated assembly that cannot be lost. The inner sleeve with magnet is permanently mounted within the housing, eliminating the risk of loss while maintaining full adjustment capability.
Solution Approach 2:
The magnet is nested within the inner sleeve, which is permanently fixed to the housing. This nested configuration ensures the magnet cannot be lost, while the outer sleeve can still rotate freely to provide adjustment capability.
4Ease of operation
If multiple switches are used to generate multiple switching pulses, then the adjustment functionality is achieved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The mechanical switching system (multiple physical switches) is replaced with a magnetic detection system. The sensor element detects the magnet's rotational position and generates switching pulses electronically, eliminating the need for multiple mechanical switches while maintaining the same functionality.
Solution Approach 2:
The magnetic field serves as an intermediary that enables the sensor element to detect rotational position and generate multiple switching pulses from a single magnetic source, replacing the need for multiple physical switches and reducing device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a robust, easy-to-manufacture round plug that meets high industrial tightness standards and allows for simple, direct parameterization of connected devices, preventing the adjustment element from being lost and ensuring reliable operation.
Implementation Method 1
a magnet (14) inserted into the outer sleeve (12), wherein the magnet (14) rotates together with the outer sleeve (12)
Implementation Method 2
an internal spring wire (13), wherein the spring wire (13) acts on the outer sleeve (12) in a springing manner with two elongated parallel ends (15)
Data Source
AI summary
The invention relates to a round plug (1) for industrial applications of the automation industry. The round plug (1) comprises a circuit board (20) in the interior of the round plug (1), together with: a sensor element (21) disposed on the circuit board (20); an evaluation circuit (22) applied to the circuit board (20); an interface (S); a collar surface (30) on the periphery of the round plug (1); an axis of rotation (31); and a sleeve-type adjustment element (10), which partly rotates about the axis of rotation (31); wherein: the adjustment element (10) consists of an inner sleeve (11), an outer sleeve (12), a spring wire (13) and a magnet (14), and the magnet (14) is inserted into the outer sleeve (12); the adjustment element (10) is pressed onto the round plug (1) such that the inner sleeve (11) is fixedly and interlockingly connected to the collar surface (30) of the round plug (1); an initial position (G) is assumed by—the movable parts of the adjustment element (10), —the outer sleeve (12) and—the magnet (14) when the spring wire (13) is in spring equilibrium; the sensor element (21) can detect the initial position (G) and, when the adjustment element (10) is rotated out of the initial position (G), can distinguish a first direction of rotation (A) from a second, opposite direction of rotation (B).