PCB Microswitch Connector With Harness Relief for Motorized Valves
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Solution Overview
Problem
Existing microswitch-based position sensors in motorized valves suffer from vulnerabilities to vibrations, electromagnetic interference, and require complex, costly soldering processes, leading to unreliable connections and increased assembly time.
Innovation Solution
A printed circuit board (PCB) connector with through holes and a slot for receiving solder pins and wires, providing an interference fit and stress relief, along with a cover for additional protection, enhances the robustness and reliability of the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are soldered directly to solder pins of microswitches, then electrical connection is established, but the connection is vulnerable to vibrations and external forces
Solution Approach 1:
A PCB is introduced as an intermediary component between the wires and microswitch solder pins. The PCB provides a robust mounting structure with through-holes for solder pins and a slot for wire insertion, isolating the solder joints from direct mechanical stress and vibrations while maintaining electrical connectivity.
Solution Approach 2:
The connection system is segmented into distinct functional zones: a soldering zone for reliable electrical connection, a slot zone for mechanical wire retention, and a stress relief zone. This segmentation allows each component to optimize its specific function without compromising overall reliability.
2Ease of manufacture
If direct wire-to-solder-pin connection is used, then assembly process is simple, but electromagnetic interference resistance is poor
Solution Approach 1:
The PCB acts as an intermediary that provides inherent electromagnetic interference shielding through its layered structure and ground planes, protecting the electrical connections without complicating the assembly process. The PCB traces and grounding system naturally filter EMI while maintaining simple wire attachment.
3Strength
If wires are secured with interference fit in slot, then mechanical robustness is improved, but manufacturing complexity increases
Solution Approach 1:
Multiple functions are merged into the PCB structure: electrical connection pathways, mechanical wire retention slot, and stress distribution features are integrated into a single component. This reduces overall assembly complexity despite the enhanced robustness of individual connection points.
Solution Approach 2:
The PCB serves multiple purposes simultaneously: it provides electrical connectivity, mechanical support, wire retention through the slot, and stress relief. This multi-functionality justifies the slightly increased structural complexity by eliminating the need for separate components for each function.
4Reliability
If PCB with slot and interference fit is used, then stress relief is provided, but manufacturing precision requirements increase
Solution Approach 1:
The slot dimensions are carefully optimized to provide an interference fit that balances mechanical retention with tolerance for manufacturing variations. The slot width and depth parameters are adjusted to ensure reliable wire retention without requiring ultra-precise manufacturing, maintaining connection durability while accommodating standard manufacturing capabilities.
Data Source
AI summary
A printed circuit board, PCB, based connector for connecting at least one wire to at least one microswitch in a position sensor for a motorised valve assembly is provided comprising a PCB comprising at least one first through hole and at least one second through hole. The at least one first through hole is configured to receive a solder pin of at least one microswitch. The at least one second through hole is configured to receive at least one wire and the PCB further comprises a slot configured to receive the at least one wire with an interference fit.