High-Temperature Sensor Connector Housing for Tamper Detection
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Solution Overview
Problem
Existing temperature sensors lack a secure connector system for lead wires, making them susceptible to tampering and potential disconnection during use.
Innovation Solution
A high temperature sensor housing with a connector assembly that includes a housing with an integrally formed connector housing, apertures, a wire assembly with a wire connector and locking element, where the first connection prevents the wire connector from detaching and the second connection prevents the locking element from detaching, ensuring secure attachment and tamper detection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a simple connector design is used, then the device complexity is reduced, but the reliability of connection is worsened
Solution Approach 1:
The wire connector is inserted through the locking element, creating a nested structure where the wire connector passes through the locking element's through-aperture. This nesting provides multiple connection points (first connection between wire connector and connector housing, second connection between locking element and connector housing) without requiring separate fastening mechanisms, thereby improving reliability while controlling complexity.
Solution Approach 2:
The connector assembly is segmented into distinct functional components: the connector housing with apertures, the wire connector with housing portion, and the locking element with through-apertures. Each segment performs a specific function (connection, passage, locking) and can be manufactured independently, allowing for improved reliability through specialized design while managing overall complexity through modular assembly.
2Reliability
If a secure connector system is implemented, then the reliability is improved, but the ease of manufacture is worsened
Solution Approach 1:
The locking element is designed with through-apertures and the wire connector with a housing portion configured to pass through these apertures before final insertion into the connector housing. This preliminary positioning through the locking element ensures proper alignment and secure attachment is achieved automatically during the insertion process, improving connector security while maintaining ease of manufacture through self-aligning features.
Solution Approach 2:
The nested arrangement where the wire connector passes through the locking element which then connects to the connector housing creates a sequential assembly process. Each component is inserted in a specific order through defined apertures, making the assembly process straightforward and repeatable, thus improving reliability without significantly increasing manufacturing difficulty.
3Reliability
If a locking mechanism is added, then the reliability against tampering is improved, but the device complexity increases
Solution Approach 1:
The locking element is nested within the connector assembly structure, with through-apertures that the wire connector must pass through to achieve proper connection. This integrated locking mechanism is built into the connector housing rather than being a separate add-on, providing tamper resistance through the required insertion sequence while minimizing increases in overall device complexity.
Solution Approach 2:
The locking function is merged with the connector housing structure itself. The locking element with its through-apertures is integrated into the housing design, and the wire connector's housing portion is designed to pass through these apertures during assembly. This merging of locking functionality into the existing connector structure provides tamper resistance without requiring a completely separate locking mechanism, thus improving reliability while controlling complexity increase.
Data Source
AI summary
Various embodiments of the teachings herein include a connector assembly comprising: a housing; a connector housing integrally formed as part of the housing; an aperture integrally formed as part of the connector housing; a wire assembly including a wire connector having a housing portion located in the aperture, the wire connector connected to the connector housing via a first connection; and a locking element connected to the connector housing via a second connection. The first connection prevents the wire connector from becoming detached from the connector housing and the second connection prevents the locking element from becoming detached from the connector housing.