Plug-in Module Housing for Mobile Machine Controllers
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Solution Overview
Problem
Mobile working machines in mining require a plug-in module that can adapt to various actuators and sensors, is robust against vibrations and explosion hazards, and supports advanced automation and diagnostics, while being lightweight and cost-effective.
Innovation Solution
A plug-in module with a plastic housing and a U-shaped strain-relief clip, featuring a board box structure with flexible conductor tracks and encapsulation for intrinsic safety and protection against environmental influences, allowing for easy connection and robustness against mechanical loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a robust housing structure is used to protect against vibrations and mechanical loads, then reliability is improved, but weight increases
Solution Approach 1:
The housing is divided into a rigid outer shell and an internal board box structure that separates the electronics from the strain-relief mechanisms. This segmentation allows the housing to provide vibration protection while using lighter materials strategically where strength is most needed.
Solution Approach 2:
The housing combines rigid plastic material for the outer shell with a separate board box structure for internal support. This composite approach provides adequate vibration and mechanical load protection while maintaining lighter weight compared to a fully metallic construction.
2Adaptability or versatility
If multiple electronics boards are connected to form a board box, then adaptability is improved, but device complexity increases
Solution Approach 1:
The board box structure serves multiple functions: it provides mechanical support for multiple electronics boards, enables flexible configuration of different sensor and actuator connections, and facilitates vibration resistance. This multi-functionality achieves adaptability without proportionally increasing complexity.
Solution Approach 2:
The electronics boards are nested within the board box structure, which itself is contained within the housing. This nested arrangement allows multiple functional boards to be integrated in a compact, organized manner that simplifies the overall device structure while maintaining versatility.
3Reliability
If a strain-relief clip is used to protect plug sockets, then reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The strain-relief clip is implemented as a separate component from the main housing, allowing it to be manufactured independently using optimized processes and then assembled into the housing. This segmentation simplifies the manufacturing of each individual part while achieving reliable plug socket protection.
4Weight of moving object
If plastic housing is used instead of metal, then weight is reduced, but strength decreases
Solution Approach 1:
The housing uses rigid plastic material combined with an internal board box structure and strain-relief clips to achieve the necessary mechanical strength. This composite construction provides adequate resistance to mechanical loads while maintaining the weight advantages of plastic compared to full metal construction.
Solution Approach 2:
The housing structure is segmented into the outer plastic shell and internal support elements (board box, strain-relief clips). This segmentation allows the plastic housing to be optimized for weight while the internal structural elements provide the necessary strength and rigidity.
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to plug-in modules for controllers of mobile working machines, having a housing (11), a connection plug (17), electronics boards (21, 22, 23) and at least one plug socket (25) for connecting actuators or sensors. In order to provide a plug-in module, being usable in onboard controllers of a mobile working machine and being also suitable for use with a wide variety of actuators or sensors, according to the invention, the housing (11) consists of a box with a front, rear and side walls (12, 13, 14) as well as a base plate (15) comprising a cutout (16) for the connection plug (17), and in that the electronics boards are forming a board box (24) by connecting two end boards (21, 23) and two side boards (22), with the board box (24) being arranged in the interior (19) of the housing (11), and with the plug socket (25) being mechanically coupled to the housing (11) by means of a strain-relief clip (30).