Modular Sensor Connection Box for Industrial Equipment
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Solution Overview
Problem
Current detector devices in industrial environments are costly and time-consuming to repair due to the need to replace entire units when the exposed connection part is damaged, leading to significant machine stoppages and productivity losses, as existing modular solutions lack reliable repeatability in electrical and mechanical connections.
Innovation Solution
A detector device with a modular structure comprising a removable connection box, a base, and sensors, where the connection box is easily interchangeable and the electrical connection is made through elastic contact points, allowing for easy replacement without affecting the integrated sensors or base, and the base is designed to absorb stress and impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the detector device is manufactured as a single-piece sub-assembly, then the structural integrity is ensured, but the repair cost and time increase significantly when the exposed part is damaged
Solution Approach 1:
The detector device is divided into two separable parts: an integrated part with sensors embedded in the equipment structure, and a connection box that can be removed and replaced independently. This segmentation allows the connection box to be replaced without affecting the integrated sensors or base, significantly reducing repair time and cost while maintaining structural integrity through the designed connection interface
2Ease of repair
If the detector device is made modular with a removable connection box, then the ease of repair is improved, but the reliability of electrical and mechanical connections deteriorates
Solution Approach 1:
The connection box integrates both mechanical fixing and electrical connection functions into a single component assembly. The mechanical interface includes integrated contact pins that simultaneously establish both mechanical attachment and electrical contact when the connection box is mounted on the base, ensuring reliable and repeatable connections while maintaining ease of replacement
3Reliability
If the entire detector device is replaced when the connection part is damaged, then the reliability is maintained, but the productivity is significantly reduced due to machine downtime
Solution Approach 1:
By segmenting the detector device into replaceable connection box and permanent integrated sensor parts, the system allows rapid replacement of only the damaged connection box without requiring machine shutdown for sensor removal or recalibration, thus maintaining reliability while minimizing productivity loss
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 design allows for quick and cost-effective replacement of the exposed connection box without affecting the integrated sensors or base, reducing downtime and improving productivity by ensuring reliable and repeatable connections, while also allowing for adaptation to different environments.
Implementation Method 1
the electrical connection is made through elastic contact points
Data Source
Figure 1~3
Figure 2A~2B
Figure 2C~2D
AI summary
The present invention relates to a detection device intended to be installed on similar industrial and/or technical equipment. This detection device comprises at least one sensor mounted in the equipment and a connection box, connected to the sensor(s) and including at least one connector for a wired connection, and incorporates functional means capable of performing processing, conditioning and/or evaluation operations on the signals generated at the sensor(s).A detector device (1) characterized in that it also comprises a base (7) simultaneously forming a mechanical mounting interface for the connection box (4) on the equipment (2) and an electrical connection interface between said box (4) and the sensor(s) (3), the mechanical and electrical connections being established by simply fitting the box (4) onto the base (7) and the functional means being physically distributed between the sensor(s) (3), the base (7) and the box (4).