Sensor Attachment Member With Alignment Protrusions
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Solution Overview
Problem
Gas detection instruments require frequent sensor replacements, which can be challenging due to their location, accessibility issues, and the need for precise alignment and robust connections, especially in industrial environments where visibility and dexterity may be limited.
Innovation Solution
A monitoring instrument with a sensor attachment member featuring alignment protrusions and notches, a beveled guide for precise connector alignment, and a toroidal spring for secure and easy sensor installation, allowing for quick replacement without the need for hand tools and accommodating misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are installed in hard-to-reach locations for monitoring, then gas detection coverage is improved, but sensor replacement becomes difficult and time-consuming
Solution Approach 1:
The sensor assembly is divided into separable components: the sensor element and the mounting bracket. This segmentation allows the sensor to be pre-assembled with its mounting structure and then installed as a complete unit in hard-to-reach locations, making future replacements simpler since the entire assembly can be removed and replaced without complex disassembly procedures.
2Strength
If traditional sensor installation methods are used, then robust connections can be achieved, but precise alignment of connectors is difficult and may cause damage
Solution Approach 1:
The mounting bracket incorporates asymmetric alignment features including a keyed slot and corresponding protrusion, along with a beveled guide surface. These asymmetric elements provide mechanical guidance that automatically aligns the connectors during installation, preventing misalignment damage while ensuring robust electrical connections once assembled.
Solution Approach 2:
The mounting bracket serves as an intermediary component between the sensor and the mounting location. It incorporates the alignment features and connector housing, mediating the connection process by providing built-in alignment guidance that eliminates the need for manual precision alignment, thereby preventing connector damage.
3Reliability
If frequent sensor replacements are required, then gas detection reliability is maintained, but installation time and operational downtime increase
Solution Approach 1:
The sensor and mounting bracket are pre-assembled into a complete sensor assembly unit before installation. This preliminary action ensures that all alignment features, connectors, and mounting elements are already correctly positioned and secured. When replacement is needed, the entire pre-assembled unit can be quickly removed and replaced without requiring on-site alignment or assembly procedures, significantly reducing installation time and operational downtime.
4Ease of operation
If alignment features are added to facilitate sensor installation, then installation ease is improved, but device complexity increases
Solution Approach 1:
The alignment features (keyed slot, protrusion, beveled guide) are merged into a single integrated mounting bracket component rather than being separate additions. This consolidation provides comprehensive alignment and mounting functionality through one piece, minimizing the number of parts and assembly steps while still delivering easy installation through the built-in alignment mechanisms.
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
Enables easy, robust, and secure sensor replacement in various conditions, ensuring reliable gas detection without damaging connectors and reducing downtime in industrial settings.
Implementation Method 1
a toroidal spring around an interior circumference of the housing to engage with an exterior circumferential groove of a sensor
Implementation Method 2
a substrate supported by the at least one compression spring, the at least one compression spring accommodating movement of the substrate
Data Source
AI summary
A monitoring instrument, such as a gas detection instrument, an easily replaceable sensor, and a mounting structure for the monitoring instrument. The monitoring instrument has a sensor attachment member that facilitates installation of the sensor. Alignment of the sensor during installation is facilitated by any of a number of alignment structures.