Sensor Assembly Head Orientation Adjustment for Wire Repair
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electrical process control sensor assemblies face issues such as the need for complete disassembly for wire repairs, wire twisting during mounting/demounting, and complex installation processes due to the requirement of disconnecting and reconnecting wires at a remote junction box, especially in hazardous environments where safety and durability are critical.
Innovation Solution
The design includes a sensor assembly where the sensing device is located entirely within the body, with a fixed connector arrangement and adjustable mounting that allows orientation adjustments, enabling external communicating members to extend directly to external circuitry without needing to disconnect from a distant junction box, and incorporates a passage for safe fluid escape, using correspondence surfaces and seals to maintain integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If wires are damaged in conventional sensor assemblies, then the sensor assembly must be demounted and repaired or replaced, but this increases loss of time and reduces ease of repair
Solution Approach 1:
The sensor assembly is divided into separable components: the sensor body mounted on the support, and the junction box as a separate removable unit. The wires connecting these components can be independently accessed and replaced without demounting the entire sensor assembly from the support structure.
Solution Approach 2:
A removable connector arrangement acts as an intermediary between the sensor body and the junction box. This connector allows wires to be disconnected and reconnected without removing the sensor assembly itself, enabling quick wire repairs by simply detaching the junction box.
2Strength
If the sensor assembly is screwed into a tapped hole in the support, then the housing is securely mounted, but the wires will rotate with the housing causing twisting and possible damage
Solution Approach 1:
The electrical connection is separated from the mechanical mounting function. The sensor body rotates with the housing during mounting, but the wires are isolated from this rotation through the removable connector arrangement, which remains stationary or can be independently positioned.
Solution Approach 2:
The removable connector arrangement serves as a mediator that decouples the rotational movement of the housing from the wires. The connector can be attached/detached independently, allowing the housing to be secured without transmitting rotational stress to the wire connections.
3Reliability
If both the sensor assembly and the separate junction box must be mounted and interconnected with cables and glands, then the system can function, but the installation process becomes complex and time-consuming
Solution Approach 1:
The sensor body and junction box are merged into a single removable unit through the connector arrangement. This allows both components to be installed and connected as one assembly, reducing the number of separate mounting operations and simplifying the overall installation process while maintaining system functionality.
Solution Approach 2:
The removable connector arrangement provides multi-functionality: it serves as both the electrical connection interface and the mechanical coupling between the sensor body and junction box. This universal interface simplifies installation by eliminating the need for separate cable glands and connection procedures.
Data Source
Figure 1~3
Figure 4
Figure 5
AI summary
An electrical process control sensor assembly 10 for sensing a process or machine parameter, the assembly 10 including a sensor body 12 and a head 14, the body 12 defining a body interior 20. The assembly includes a sensing device 22 at least partially located in the body interior 20. The head 14 defines a head interior 24 which communicates with the body interior 20. The assembly 10 includes a connector arrangement 26 located in the head interior 24. The assembly 10 includes internal communicating members 28 extending between the sensing device 22 and the connector arrangement 26, the connector arrangement 26 connecting, in an installed condition, the internal communicating members 28 to external communicating members 30 to permit electrical communication therebetween. The head 14 defines a port 34 through which the external connecting members 30 are located in the installed condition. The assembly 10 includes a mounting 48 for mounting the head 14 to the body 12 which is arranged to permit adjustment of the orientation of the head 14 relative to the body 12.