LRU Motor Sensor Socket for Corrosion-Free Field Replacement
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Solution Overview
Problem
Existing motor sensor systems for cooling towers face issues with corrosion, contamination, and the need for complex communication cable and gland systems, leading to maintenance challenges and increased costs.
Innovation Solution
The Line Replaceable Unit (LRU) sensor system is designed to be installed within the motor cavity, utilizing internal wireways for power, communication, and grounding, and featuring a plug-and-play configuration for easy replacement without the need for skilled electricians.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If communication cables are used to connect sensors to external devices, then sensors can provide monitoring functions, but the cables are susceptible to corrosion, contamination, and breakage in harsh environments
Solution Approach 1:
The patent extracts the communication cable and external connector from the sensor system, eliminating the vulnerable external wiring. Sensors are wired directly to the motor controller board through internal routing, removing the cable and gland assembly that is susceptible to corrosion and contamination in harsh environments.
Solution Approach 2:
The patent merges the sensor, wiring, and controller into a single integrated unit. The sensor is mounted directly on or near the motor controller board with internal wiring connections, combining previously separate components (sensor, cable, connector, controller) into one sealed assembly that eliminates external vulnerable connections.
2Object-affected harmful factors
If sensors are built into the motor framework, then they are protected from environmental damage, but they cannot be replaced in the field and require motor shutdown for maintenance
Solution Approach 1:
The patent segments the sensor system into a replaceable sensor module and a permanent motor controller board. The sensor is mounted on the controller board in a manner that allows it to be removed and replaced independently without removing the entire controller or shutting down the motor, enabling field maintenance while maintaining environmental protection.
3Strength
If complex cable and gland systems are used to protect wiring, then wiring is protected from some damage, but the system complexity and maintenance difficulty increase
Solution Approach 1:
The patent removes the complex external cable and gland protection system entirely. Instead of protecting external cables with conduits and glands, the wiring is routed internally within the sealed motor housing, eliminating the need for complex external protection mechanisms while maintaining wiring integrity.
4Use of energy by moving object
If sensors require external communication cables with multiple terminals, then power and communication signals can be transmitted, but the connection complexity and risk of sparking in hazardous environments increase
Solution Approach 1:
The patent combines power, communication, and signal wiring into a single integrated internal routing system within the sealed motor housing. All electrical connections are made internally without external cables or connectors, eliminating potential sparking points while maintaining full power and communication functionality through the sealed enclosure.
Data Source
AI summary
A motor has a housing which comprises a cavity and a socket accessible from outside the housing. The socket has an interior surface. The motor includes a LRU sensor system which comprises an LRU sensor having electrical conductors and internal sensor wiring that is electrically connected to the electrical conductors and electrical conductors on the interior surface of the socket, wherein when the LRU sensor is positioned in the socket, the electrical conductors on the LRU sensor contact the electrical conductors on the interior surface of the socket.