Rotatable Sensor Electrical Connector Design for Cable Kinking
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Solution Overview
Problem
Existing electrical connectors in sensor systems fail to maintain reliability and durability under cyclic rotation and high vibration conditions, leading to cable breakage due to kinking and tension.
Innovation Solution
A compact, pivotable electrical connector design with a plug connection positioned close to the sensor axis minimizes kinking and is secured with a ball bearing and lubricated stranded wires to reduce friction and stress, ensuring robustness and longevity in tight spaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the electrical connector is positioned perpendicular to the sensor axis, then the cable connection is easier to access, but the cable is subjected to kinking and tension during rotation leading to breakage
Solution Approach 1:
The patent repositions the electrical connector from a perpendicular orientation to an orientation substantially parallel with the sensor's central extension axis. This dimensional change in connector placement moves the cable connection point along the sensor axis, fundamentally altering the cable's stress distribution during rotation and eliminating kinking while maintaining accessibility.
Solution Approach 2:
Instead of positioning the connector perpendicular to the sensor axis as in conventional designs, the patent inverts this arrangement by placing it parallel to the axis. This inversion of the standard configuration fundamentally changes how rotational forces are transmitted through the cable, preventing the harmful kinking effect.
2Area of stationary object
If the sensor system is designed for tight installation spaces, then the installation footprint is reduced, but the cable connection becomes more susceptible to kinking and tension
Solution Approach 1:
By repositioning the connector along the sensor axis rather than perpendicular to it, the patent creates a more favorable spatial arrangement for cable routing within tight spaces. This dimensional repositioning allows the cable to exit in a direction that minimizes bending radius and stress concentration, enabling reliable operation in compact installations.
3Adaptability or versatility
If the connector is rotated frequently cyclically, then the sensor can adapt to different measurement positions, but the cable connection experiences increased stress leading to failure
Solution Approach 1:
The patent positions the connector parallel to the sensor axis, which fundamentally changes the cable's stress profile during cyclic rotation. This dimensional repositioning allows the cable to accommodate rotational movements without developing kinks or excessive tension, enabling frequent repositioning while maintaining connection integrity.
Solution Approach 2:
The patent modifies the connector's orientation parameter from perpendicular to parallel relative to the sensor axis. This parameter change fundamentally alters the mechanical stress distribution on the cable during rotation, reducing both kinking and tension forces to levels that preserve cable longevity under frequent cyclic operation.
4Ease of operation
If the plug connection is positioned far from the sensor axis, then the cable has more space to route, but the cable is subjected to greater kinking and tension during rotation
Solution Approach 1:
The patent repositions the connector from a location far from the sensor axis to one that is substantially parallel with and close to the axis. This dimensional repositioning fundamentally changes the cable's stress distribution during rotation, eliminating the kinking problem that occurs when the connector is positioned far from the axis while maintaining adequate routing space.
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 effectively prevents cable breakage and ensures reliable operation in harsh environments by reducing kinking and tension on the sensor cables, even under repeated cyclic rotation and high vibration conditions.
Implementation Method 1
secured with a ball bearing and lubricated stranded wires to reduce friction and stress
Implementation Method 2
secured with a ball bearing and lubricated stranded wires to reduce friction and stress
Data Source
AI summary
A sensor system for measuring pressure, temperature, force, or fill level, whereby an electrical plug connection is made especially robust and reliable for frequent, cyclic pivoting movements.