Plug Gauge Quick Coupling Mechanism for Rapid Probe Replacement
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Solution Overview
Problem
Existing plug gauges are complex, expensive, and time-consuming to reconfigure for different measuring ranges due to cumbersome coupling systems and electrical connectors, requiring skill and time for replacement, with limited compactness and high production costs.
Innovation Solution
A modular apparatus with a hollow handle and quick coupling mechanism featuring a position transducer and wireless transmission system, allowing for easy and rapid replacement of probes using a deformable locking mechanism, optimizing component parts for flexibility and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a mechanical coupling system with threaded couplings and electrical connectors is used to connect the probe to the handle, then the probe can be replaced for different measuring ranges, but the replacement operation requires skill and time, reducing productivity
Solution Approach 1:
The coupling mechanism is divided into distinct functional elements: a coupling element with radial locking portions, a clamping element for actuation, and reference surfaces for positioning. This segmentation allows each component to perform its specific function efficiently, enabling rapid probe replacement without requiring complex assembly operations.
Solution Approach 2:
The locking portions are designed to be deformable and movable between locked and unlocked positions. The clamping element dynamically actuates this transition, allowing the probe to be quickly secured or released. This dynamic mechanism eliminates the need for threaded fastening operations, significantly reducing replacement time.
2Reliability
If a mechanical coupling system with radial screws and through bores is used to connect the probe to the handle, then the probe can be securely attached, but the coupling system becomes complex and expensive, increasing device complexity
Solution Approach 1:
The traditional threaded coupling system and separate electrical connectors are extracted and replaced by an integrated coupling mechanism. The locking portions directly engage with reference surfaces on the probe, providing both mechanical attachment and electrical connection functionality in a single simplified structure.
Solution Approach 2:
The coupling mechanism merges the functions of mechanical attachment and electrical connection into a single integrated system. The locking portions simultaneously provide mechanical retention and serve as contact points for electrical signals, eliminating the need for separate threaded couplings and electrical connectors.
3Adaptability or versatility
If the probe includes a measuring cell with transducer and feelers as an integrated complex unit, then the probe can be replaced for different nominal dimensions, but the probe becomes expensive and complex, increasing manufacturing costs
Solution Approach 1:
The probe is segmented into simpler mechanical components (feelers, transmission mechanism, stem) that can be manufactured independently at lower cost. The complex transducer electronics are separated and housed in the handle, allowing the probe to be produced as a simpler mechanical assembly that can be rapidly manufactured for different measuring ranges.
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
The solution enhances flexibility, reduces costs, and simplifies handling and retooling, enabling rapid and accurate measurement across various ranges with reduced overall dimensions and improved reliability.
Implementation Method 1
a position transducer with a stationary part that is stationary with respect to the handle and a movable part that is movable along a substantially longitudinal direction
Data Source
AI summary
A plug gauge (1) includes a support and protection frame with a handle (2) that defines a longitudinal axis and houses a position transducer (25) and electronic devices for wirelessly transmitting electrical signals indicative of a dimension to be checked. The gauge also comprises a probe (6) including a mechanical armset (7) provided with at least one movable feeler (10), and a transmission mechanism with a stem (17) transmitting movements of the feeler to the position transducer housed in the handle. The probe is connected to the handle by means of a quick coupling mechanism (5) with deformable locking portions (52), the radial arrangement of which is controlled by a clamping element (60).