Modular Combustible Gas Sensor for Easy Replacement
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Solution Overview
Problem
Existing combustible gas detectors require complete replacement when the integrated gas sensor fails, leading to unnecessary waste and increased maintenance costs, as the sensor has a limited service life of about three years.
Innovation Solution
A modular combustible gas sensor design where the sensor unit is detachably mounted to a sensing device body, allowing for easy replacement of the sensor module while keeping the rest of the device intact, with a microcontroller for calibration and a flexible buffer gasket for secure positioning, enabling the device to sense multiple gases and prevent vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the gas sensor is integrated in the combustible gas sensing device, then the device structure is simplified, but the entire device needs to be replaced when the sensor fails
Solution Approach 1:
The patent divides the combustible gas sensing device into separate modular components: the sensor unit with its enclosure and the main sensing device body. This segmentation allows the sensor unit to be independently replaced without replacing the entire device, resolving the contradiction between simplified structure and ease of repair.
2Reliability
If the entire combustible gas sensing device is replaced when the sensor fails, then reliability is ensured, but maintenance costs increase and waste is generated
Solution Approach 1:
The patent extracts the sensor unit as a separate replaceable module from the main sensing device body. This allows only the failed sensor unit to be removed and replaced, while the functional main body remains in use, thereby ensuring reliability while reducing waste and maintenance costs.
3Ease of repair
If the sensor unit is detachably mounted, then replacement is simplified, but the device complexity increases
Solution Approach 1:
The patent implements segmentation by creating distinct modular components with standardized interfaces. The sensor unit has a plug connector that mates with the sensing device body, providing simple detachable mounting that facilitates easy replacement without significantly increasing overall device complexity.
4Adaptability or versatility
If calibration is performed on-site after replacement, then adaptability is improved, but measurement precision may be affected
Solution Approach 1:
The patent incorporates a microcontroller on the circuit board that can pre-calibrate sensing parameters for different gas types before the sensor unit is installed. This preliminary action ensures measurement precision is maintained while allowing adaptability to different gas applications through software configuration.
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
This modular design reduces maintenance costs and extends the lifespan of the device by allowing only the sensor module to be replaced, eliminating the need for full device replacement and simplifying on-site calibration, while ensuring accurate and efficient gas detection.
Implementation Method 1
Gas sensors often employ catalytic combustion type sensors
Data Source
AI summary
A combustible gas sensor module and a combustible gas sensing device. The combustible gas sensor module includes an enclosure including a first end and a second end opposite to each other; a plug connector disposed at the first end of the enclosure for connecting to a sensing device body of a combustible gas sensing device; a sensor unit disposed at the second end of the enclosure for sensing combustible gas; and a circuit board disposed in the enclosure and respectively connected to the plug connector and the sensor unit, with a microcontroller provided thereon.