Modular Sensor Arrangement with Coded Plug-Connection Parts
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Solution Overview
Problem
Existing sensor arrangements in systems like heating plants face challenges in preventing the interchange of electrical connectors at measuring points, leading to increased manufacturing complexity and the need for multiple variants of sensors to ensure correct assignment.
Innovation Solution
A sensor arrangement comprising a connector piece and a sensor element that are connectable only through specific, dissimilar connection parts, preventing interchange by using mechanical coding and latching features, allowing for the same sensor elements to be used with various connector pieces, simplifying manufacturing and requiring only the sensor element as a spare part during maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are coded with dissimilar plug-connection parts to prevent interchange, then reliability of sensor assignment is improved, but device complexity increases due to multiple sensor variants
Solution Approach 1:
The sensor system is divided into two independent segments: a universal sensor element and a connector piece with coded plug-connection parts. The sensor element contains the sensing components (temperature sensor, housing, probe), while the connector piece contains the electrical connector and coding features. This segmentation allows the sensor element to remain identical across all variants, while differentiation is achieved through the connector piece alone.
Solution Approach 2:
The sensor element is designed as a universal component that can be used with multiple types of connector pieces. The same sensor element (with identical sensing capabilities, housing, and probe) can be connected to different connector pieces through the standardized connection interface, allowing one sensor element design to serve multiple sensor arrangement variants.
2Reliability
If multiple sensor variants are manufactured to prevent connector interchange, then reliability of sensor assignment is improved, but manufacturing complexity increases
Solution Approach 1:
Manufacturing is segmented into two independent production streams: sensor element manufacturing and connector piece manufacturing. The sensor element is manufactured once with a standardized design, while connector pieces are manufactured separately with different coded plug-connection parts. This eliminates the need to manufacture multiple complete sensor variants, reducing manufacturing complexity.
Solution Approach 2:
A single sensor element design serves multiple purposes by being compatible with various connector pieces. This universality means that the same sensor element can be paired with different connector pieces to create different sensor arrangement variants, eliminating the need to manufacture multiple specialized sensor types.
3Reliability
If complete sensor assemblies are delivered pre-assembled with coded connectors, then interchange prevention is improved, but inventory complexity increases
Solution Approach 1:
The spare parts inventory is segmented into two categories: universal sensor elements and connector pieces. Since the sensor element is universal and compatible with all connector types, only one type of sensor element needs to be kept in inventory. The connector piece remains at the measuring point, so only the sensor element requires spare parts availability.
Solution Approach 2:
The universal sensor element can replace sensor elements in any sensor arrangement variant, regardless of which connector piece is used. This universality dramatically reduces spare parts inventory requirements, as a single sensor element design can service multiple different sensor arrangement types.
4Ease of repair
If sensor elements are made modular and separable from connector pieces, then ease of maintenance is improved, but device complexity increases
Solution Approach 1:
The sensor arrangement is segmented into two separable components: the sensor element and the connector piece. The sensor element can be easily detached from the connector piece through the connection interface, allowing quick replacement of the sensor element without disturbing the connector piece or the measuring point installation.
Solution Approach 2:
The standardized connection interface between sensor element and connector piece enables universal compatibility. The same connection mechanism works across all sensor arrangement variants, simplifying the maintenance process regardless of which specific variant is being serviced.
Data Source
AI summary
A sensor arrangement and a set of sensor arrangement elements are disclosed. In an embodiment the sensor arrangement includes a connector piece having a first connection part; and a sensor element having a second connection part, which is connectable to the first connection part or is connected to the first connection part, wherein the sensor arrangement, in case the connector piece and the sensor element are connected to one another, includes a plug-connection part.