Sensor Assembly Connector Mechanism for Blind Mating
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Solution Overview
Problem
Existing sensor systems require manual alignment of pin arrays, which can lead to damage and do not allow for blind mating, making them cumbersome and prone to errors in hazardous environments.
Innovation Solution
A connector mechanism with key components that align and interlock to facilitate safe and quick attachment and detachment of sensor cartridges to sensor head assemblies, enabling blind insertion and reducing the risk of pin damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual alignment of pin array is required, then connection reliability can be ensured, but operation complexity increases and pin damage risk increases
Solution Approach 1:
The key components are pre-configured on both the sensor cartridge and head assembly before connection. These keys protrude or recess in predetermined positions, automatically guiding alignment when the components are brought together, eliminating the need for manual alignment operations.
Solution Approach 2:
The key components act as intermediary elements between the sensor cartridge and head assembly. These keys engage with corresponding recesses to mediate the connection process, ensuring proper alignment and protecting the pin array from damage during mating operations.
2Manufacturing precision
If visual inspection is required for alignment, then connection accuracy can be ensured, but productivity decreases in hazardous environments
Solution Approach 1:
The connector mechanism is designed to be self-aligning through the key components. When the sensor cartridge is brought near the head assembly, the keys automatically guide the components into proper alignment without requiring visual inspection or manual intervention, enabling blind mating operations.
Solution Approach 2:
The key components are pre-configured with specific geometries that automatically establish correct orientation during the approach phase. This preliminary configuration ensures that when the components mate, alignment is already achieved, eliminating the need for post-approach visual verification.
3Adaptability or versatility
If pin array is exposed, then connection flexibility is maintained, but pin damage risk increases during alignment attempts
Solution Approach 1:
The key components are positioned to engage first during the connection process, before the pin array becomes exposed or vulnerable. This preliminary engagement of the keys protects the pins from misalignment forces and damage that would occur during attempted connection without proper guidance.
Solution Approach 2:
The key components serve as protective intermediaries that engage with the opposing component before the pin array is exposed. This intermediary engagement creates a guided pathway that prevents direct exposure of the vulnerable pins to misalignment forces, reducing damage risk while maintaining connection flexibility.
Data Source
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AI summary
The subject matter described herein relates to a connector mechanism for safely and quickly attaching or detaching a sensor. The connector mechanism includes a sensor head assembly comprising a detector body with an internal channel and an open distal end. The connector mechanism also includes a sensor head attachment connector (sensor HAC) located within the channel. The HAC may be oriented to face the distal end and recessed within the channel remote from the distal end. The HAC may include a first electrical connection having at least a first contact member. The HAC may include a first key component that is located in a fixed location relative to the first contact member. The connector mechanism also includes a sensor cartridge comprising a cartridge housing that includes a probe component. The sensor cartridge may be configured to be at least partially inserted through the open distal end into the internal channel of the detector body. The sensor cartridge may also include a second electrical connection having at least a second contact member configured to mate with the first contact member. The sensor cartridge may also include a second key component that is located in a fixed location relative to the second contact member. The first and second key components engage one another before the first and second contact members engage one another.