Connection Adapter for Sensor Plug Face Adaptation
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Solution Overview
Problem
Existing sensor and actuator connection systems require multiple parts and frequent changes when adapting plug faces, leading to inefficiencies and increased costs due to the need for constant adaptation of plug connectors with every change.
Innovation Solution
A connection adapter is introduced that serves as an electromechanical interface between sensors, actuators, and plug connectors, allowing for a uniformly shaped interface between the sensor/actuator and the adapter, enabling modular mounting and adaptation of different plug faces, thus eliminating the need for constant changes in the entire system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the plug face of the sensor or actuator is changed, then the sensor or actuator can be adapted to different applications, but the entire sensor or actuator must be changed, increasing cost and complexity
Solution Approach 1:
The connection system is divided into three separate components: the sensor/actuator with its plug face, the connection adapter with a standardized interface on one side and a configurable interface on the other, and the plug connector. This segmentation allows the plug face configuration to be changed by replacing only the connection adapter rather than the entire sensor or actuator, thereby reducing device complexity while maintaining adaptability.
Solution Approach 2:
The connection adapter serves as an intermediary component between the sensor/actuator plug face and the plug connector. It has a standardized interface that couples with the sensor/actuator and a configurable interface that adapts to different plug connector requirements. This intermediary allows flexible adaptation of plug faces without changing the core sensor or actuator, resolving the contradiction between adaptability and device complexity.
2Reliability
If the plug connector is adapted to match every change in sensor or actuator plug face, then proper electrical connection is maintained, but the number of parts increases and production becomes less economical
Solution Approach 1:
The connection adapter is designed with a universal standardized interface that can couple with various sensor or actuator types. This single adapter design can be configured with different plug faces to match different plug connector requirements, eliminating the need to produce multiple specialized plug connectors. This multi-functionality maintains reliable electrical connections while significantly improving manufacturing economy by reducing the variety of parts that must be produced and inventoried.
3Productivity
If a standardized interface is used between sensor/actuator and connection adapter, then modular mounting is enabled and production is economical, but the ability to adapt to different plug connector configurations is reduced
Solution Approach 1:
The connection adapter incorporates a dynamically configurable interface that can be customized to match different plug connector configurations. The standardized interface side remains fixed for efficient modular mounting, while the other interface can be adapted through design variations in the connection adapter itself. This dynamic configurability allows the system to maintain high production efficiency through standardized manufacturing while preserving the ability to adapt to different plug connector configurations.
Data Source
AI summary
A connection adapter is configured and shaped to be connected between the connection side of a sensor or of an actuator and the input side of a plug connector in order to adapt different plug faces of the sensor or actuator and of the plug connector to each other. The connection adapter has a plug base facing toward the plug connector and with contact chambers and comprises a fastening area facing toward the sensor or actuator.