Sensor Calibration Access via Sealing Grommet and Plug
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Solution Overview
Problem
Conventional sensors are vulnerable to environmental contaminants due to the configuration of calibration points, which can be exposed during the sealing process, compromising their robustness and integrity in harsh environments.
Innovation Solution
A sensor design featuring a sealing grommet with an axial hole for access to calibration points during production, followed by a grommet plug and encapsulant sealing material to seal the points, preventing further access and enhancing environmental protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If wires are connected to calibration points and the sensor is sealed at those points, then calibration access is provided during production, but the sensor becomes vulnerable to contaminants in its environment
Solution Approach 1:
The sealing grommet is divided into two functional sections: an axial hole portion that provides calibration access and a sealed portion that protects against contaminants. This segmentation allows the same component to serve both calibration and sealing functions without compromising either.
Solution Approach 2:
The sealing grommet acts as an intermediary component between the calibration points and the external environment. It provides a controlled passage for calibration operations while blocking contaminant ingress, mediating between the need for access and the need for protection.
2Reliability
If the sensor is fully sealed to protect against environmental factors, then robustness is improved, but access to calibration points is precluded
Solution Approach 1:
The axial hole in the sealing grommet is pre-configured to provide calibration access during production operations. This preliminary design feature ensures that calibration can be performed before final sealing, eliminating the need to break seals for calibration purposes.
Solution Approach 2:
The sealing system transitions from an open state (axial hole providing access) during calibration to a sealed state (hole blocked with sealant) after calibration. This dynamic behavior allows the system to adapt its sealing characteristics based on operational phase.
3Ease of operation
If calibration points are left accessible for future adjustments, then ease of operation is improved, but sensor integrity and sealing are compromised
Solution Approach 1:
The sealing grommet with axial hole provides self-contained calibration access that does not require compromising the overall seal. The calibration function is integrated into the sealed structure itself, allowing adjustments without external intervention that would breach the seal.
Solution Approach 2:
The sealing grommet uses a flexible sealing structure with an axial hole that can accommodate calibration operations. The grommet material and design allow for controlled access while maintaining the flexibility and integrity of the sealed environment.
Data Source
AI summary
An example sensor includes a PCB mounted in an internal chamber of housing, wherein the PCB comprises calibration electrical contact points; a sealing grommet mounted in the internal chamber, wherein the sealing grommet comprises an axial hole aligned with the calibration electrical contact points, thereby providing access to the calibration electrical contact points of the PCB; a grommet plug disposed in the axial hole of the sealing grommet; a sensing element disposed in the housing and electrically-coupled to the PCB via an electrical connection; an encapsulant sealing material deposited on the sealing grommet and the grommet plug; and an external cable connected to the PCB and extending through the sealing grommet and through the encapsulant sealing material.