Sensor Mounting Adapter With Coupling Ring for Pressurized Removal
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Solution Overview
Problem
Existing sensor mounting systems for pressurized pipelines, such as those using NPT threads or union nuts, pose risks of injury and leakage during installation and removal due to uncontrolled medium release, and require complex and wear-prone procedures for calibration and sealing.
Innovation Solution
A measuring arrangement with a sensor unit, mounting adapter, and coupling ring that includes peg elements and guide contours, allowing for secure locking and pressure indication, enabling safe installation and removal by adjusting the peg element's position through rotary and insertion movements, and incorporating a sealing ring for secure connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a sensor with plastic housing is directly screwed to a pressurized pipeline using NPT threads, then the sensor can be mounted on the pipeline, but there is a high risk of injury to the user and uncontrolled medium escape during installation and removal
Solution Approach 1:
The patent introduces an intermediate mounting system consisting of a mounting adapter and coupling ring that acts as a mediator between the sensor and the pressurized pipeline. The mounting adapter is permanently fixed to the pipeline, while the coupling ring provides a safe, tool-free connection for the sensor. This intermediary system eliminates the need for users to directly thread sensors onto pressurized pipelines, thereby preventing injury and uncontrolled medium release while maintaining mounting simplicity.
2Ease of operation
If a directly-mounted NPT sensor is unscrewed from a pressurized pipeline, then the sensor can be removed, but the measured medium flows uncontrolled into the user area causing injury risk
Solution Approach 1:
The mounting system is pre-installed on the pipeline before sensor operation. The mounting adapter is permanently fixed to the pipeline, and the coupling ring is pre-positioned to receive the sensor. When removing the sensor, the user simply detaches it from the coupling ring without needing to unscrew threads from the pressurized pipeline. The coupling ring remains in place, maintaining the seal and preventing uncontrolled medium flow toward the user.
3Strength
If a sensor with plastic housing is screwed to the line with low tightening torque, then the risk of glass electrode breakage is reduced, but vibrations and line pressure cause leakage over time
Solution Approach 1:
The mounting system segments the connection into three independent parts: the mounting adapter permanently fixed to the pipeline, the coupling ring providing the sensor connection, and the sensor itself. This segmentation allows the mounting adapter to be securely fastened to the pipeline with high torque without risking glass electrode breakage, while the coupling ring provides a separate, tool-free connection for the sensor that maintains sealing under vibration and pressure conditions.
4Productivity
If a twist-lock system is used with a quarter turn locking mechanism, then the sensor can be quickly mounted, but complete ejection occurs when the locking pin is removed causing uncontrolled medium release
Solution Approach 1:
The coupling ring serves as an intermediary that provides a tool-free, quarter-turn locking mechanism for quick sensor mounting while maintaining a secure connection. The coupling ring's internal threading and locking features provide sufficient holding force without requiring a locking pin that, when removed, would cause complete ejection. The mounting adapter remains permanently fixed to the pipeline, ensuring that even if the sensor is detached, the connection point remains sealed and prevents uncontrolled medium escape.
Data Source
AI summary
A measuring arrangement is disclosed that ensures safe installation and removal of a sensor relative to a wall of a measuring volume. The sensor is movably arranged in a mounting adapter that is fixedly arranged in the wall. The sensor is held in the mounting adapter by the connection of a coupling ring to the mounting adapter. A recess is provided for guiding a peg element. The position of the peg element in the recess is adjustable in, or counter to, the insertion direction of the sensor by a rotary and/or insertion movement of the coupling ring. The sensor and coupling ring are movable together by pressurization so that the peg element is arranged in a first locking position when pressurization by the medium is present in the measuring volume.