Modular Sensor Box Design for Industrial Automation
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Solution Overview
Problem
Current sensor boxes for industrial automation are cumbersome, inflexible, and require multiple sizes to accommodate varying numbers of sensors, leading to bulkiness and increased storage needs, as they are designed for specific maximum numbers of connections rather than optimized for the exact number of sensors used.
Innovation Solution
A modular sensor box design featuring structurally identical master and slave modules with interchangeable electronic circuits, allowing for customization based on the number of sensors, where modules can be connected in series or parallel to form a flexible and adaptable system, minimizing component storage and optimizing dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If sensor boxes are designed for specific maximum numbers of sensors (standard sizes), then compatibility with different sensor quantities is achieved, but the bulk is greater than necessary and storage requirements increase
Solution Approach 1:
The sensor box is divided into modular units, each capable of accommodating a specific number of sensors. Instead of creating one large box for maximum capacity, the system uses multiple smaller modular boxes that can be selectively assembled based on the actual number of sensors required, thereby reducing storage requirements while maintaining versatility.
Solution Approach 2:
The sensor box system transitions from static standard sizes to a dynamic modular configuration. The number of modular units can be adjusted based on the specific application requirements, allowing the system to adapt its capacity flexibly rather than being fixed in predetermined standard sizes.
2Stability of the object's composition
If sensor boxes are designed as box-like structures with fixed passages, then structural stability is maintained, but the shape is cumbersome and occupies excessive space in automation devices
Solution Approach 1:
The traditional single large box-like structure is segmented into multiple smaller modular units. Each module maintains structural stability through its own compact housing with integrated passages, but the overall system occupies significantly less space when configured for fewer sensors, as only the necessary number of small modules are deployed.
Solution Approach 2:
The design transitions from a two-dimensional planar expansion (larger box footprint) to a three-dimensional stacked or series configuration. Multiple modular units can be arranged in series along a linear path, allowing the system to maintain structural integrity while minimizing the overall area occupied on the automation device surface.
3Adaptability or versatility
If multiple standard-sized sensor boxes are produced for different sensor quantities, then all connection needs are met, but device complexity and manufacturing variety increase
Solution Approach 1:
All modular units are designed with identical structures, housing configurations, and passage arrangements, making them universally interchangeable. This single standardized design can serve all sensor quantity requirements by simply varying the number of modules used, eliminating the need for multiple specialized box designs and reducing manufacturing complexity.
Solution Approach 2:
The system allows for easy assembly and disassembly of modular units. When a different number of sensors are required, excess modules can be discarded or recovered for future use, while only the necessary number of identical modular units are assembled into the final configuration, simplifying manufacturing and inventory management.
4Reliability
If fixed passages are positioned in predefined locations, then cable connection consistency is maintained, but flexibility in wiring configurations is reduced
Solution Approach 1:
The passage system is segmented and replicated across multiple modular units. Each module contains its own set of passages positioned in consistent predefined locations, ensuring reliable cable connections within each module. The modular architecture allows these consistent local connections to be combined in various configurations to achieve different overall wiring arrangements.
Solution Approach 2:
The passage configuration transitions from a fixed single-location design to a dynamic distributed arrangement. While each individual module maintains consistent predefined passage positions for reliable connections, the system as a whole can be configured in different arrangements (series, parallel, stacked) to accommodate various wiring needs, providing flexibility at the system level.
Data Source
AI summary
A module for a sensor box for automation devices and a respective sensor box includes a containing body, an electronic circuit housed inside the containing body and is designed to define a so-called master module, or a so-called slave module. The module also includes one or more main electric contacts emerging from a first side of the containing body, at least one passage for a respective connecting cable for the connection to an outside device and one or more openings, each arranged on a second side of the containing body which is opposite to said first side. The main electric contacts and the openings are arranged in corresponding positions on the first side and on the second side, so that all the main electric contacts emerge from the first side in a position corresponding to that of at least one opening on the second side.