Modular Humidity Sensor with Removable Circuit Board Assembly
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Solution Overview
Problem
Existing humidity sensors mounted on surfaces like walls or ducts require complex disassembly and recalibration for maintenance, often due to limited space and awkward access, leading to inefficient servicing and replacement processes.
Innovation Solution
A humidity sensing apparatus with a modular circuit board assembly that allows the electronics to be easily removed as a single unit from the housing without displacing the housing, enabling servicing and replacement of sensor modules at a convenient location, using a connector system for electrical and mechanical rigidity, and a sealing device for air isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the humidity sensor is mounted on the outside surface of a duct with a sleeve extending through an aperture, then the sensor can detect humidity levels within the duct, but the sensor requires complex disassembly and recalibration for maintenance due to limited space and awkward access
Solution Approach 1:
The sensor assembly is divided into separate functional modules: a mounting enclosure that remains on the duct exterior, a removable sleeve that extends through the aperture, and a sensing unit that can be independently removed from the sleeve. This segmentation allows the sensing unit to be accessed and serviced without removing the entire mounting enclosure, resolving the contradiction between maintaining reliable humidity detection and enabling easy maintenance.
Solution Approach 2:
The sensing unit is extracted as a separate, removable component from the sleeve, which itself is separate from the mounting enclosure. This extraction allows the sensing unit to be removed and serviced at a convenient location without displacing the housing or requiring complex disassembly, directly addressing the ease of repair requirement while preserving the reliable detection function.
2Measurement precision
If the sensing unit is mounted within the sleeve for sensing humidity, then the sensor can continuously monitor humidity levels, but the sensor requires recalibration during maintenance due to limited space
Solution Approach 1:
The device is segmented into independently serviceable modules where the sensing unit can be removed from the sleeve without affecting the mounting enclosure. This segmentation eliminates the need for complex disassembly and recalibration procedures, as the sensing unit can be replaced as a complete module rather than requiring internal disassembly and recalibration of individual components.
Solution Approach 2:
The sensing unit is designed to be pre-assembled and pre-calibrated as a complete module before installation. This preliminary action ensures that calibration is performed under controlled conditions during manufacturing, eliminating the need for field recalibration during maintenance while preserving measurement precision.
3Ease of repair
If the sleeve is releaseably attached to the mounting enclosure via a swage nut, then the sleeve and sensing unit can be removed for servicing, but the mounting enclosure remains in place requiring complex disassembly
Solution Approach 1:
The mounting structure is segmented into a permanent mounting enclosure and a removable sleeve assembly. The sleeve is releaseably attached to the mounting enclosure via a swage nut, allowing the sleeve and sensing unit to be removed as a complete assembly for servicing without requiring disassembly of the mounting enclosure itself. This segmentation dramatically simplifies the disassembly procedure while maintaining ease of repair.
Solution Approach 2:
The sleeve and sensing unit are extracted as a removable assembly from the mounting enclosure through the releaseable attachment mechanism. This extraction allows servicing to be performed at a convenient location without requiring removal of the mounting enclosure, reducing disassembly complexity while maintaining accessibility for repair.
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
Simplifies the maintenance and replacement process by allowing for remote servicing of the sensor modules, reducing the need for recalibration and minimizing the effort required for field repairs, while maintaining mechanical protection and signal integrity.
Implementation Method 1
a sensing unit mounted within the sleeve and positioned within the duct for sensing the level of humidity within the duct
Data Source
AI summary
An apparatus (10) for sensing a condition, such as humidity, through an opening (20) in a surface (12) such as a duct or wall. A housing (14) includes an outer section (16) mounted on the surface and a probe section (18) extending into the duct or wall. A circuit board assembly (32) is mounted within the housing and includes a user interface section (34) within the housing outer section and a sensor section (36) rigidly connected to the user interface section and extending into the housing probe section. The sensor section may be integrated into the circuit board assembly by a rigid connector (42) allowing easy removal and field replacement of the sensor section. A sealing device (56) isolates the housing outer section from the air within the duct or wall. A flexible grounding connection (66) provides electrical grounding of the circuit board assembly and a degree of mechanical support.