Sensor Housing Plug Connection for Flexible Cover Assembly
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Solution Overview
Problem
Existing sensor housings face challenges in easily and reliably connecting the cover and base parts due to restrictive contact pins, which complicates assembly and disassembly, requiring a balance between contact reliability and ease of connection.
Innovation Solution
A sensor housing design featuring a plug connection part with electrically conductive contact means and surfaces, allowing for a tool-free, intuitive connection between the head and connection parts, providing a high degree of freedom in directional movement and alignment, and incorporating a terminal connection block for establishing an electrical connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If contact pins are made longer and more precisely fitting to improve contact reliability, then the difficulty of separating or connecting the lid and base increases
Solution Approach 1:
The connection part is divided into two separate parts (lid and base) that can be easily assembled and disassembled. The contact pins are segmented into multiple independent contacts rather than a single rigid connection, allowing the parts to be joined and separated without excessive force while maintaining reliable electrical contact.
Solution Approach 2:
The contact pins are designed with specific dimensional parameters (length, diameter, flexibility) that optimize both contact reliability and assembly ease. The pins are long enough to ensure reliable contact but not excessively long to prevent difficult assembly, and their flexibility parameter allows them to accommodate minor misalignments during joining.
2Reliability
If multiple contact pins are used to establish electrical connection, then the directional freedom for joining lid and base is restricted, but electrical connection reliability is improved
Solution Approach 1:
The connection part design allows the lid and base to be joined from multiple directions (front, rear, left, right sides) while maintaining reliable electrical contact through multiple contact pins. The terminal block and contact pin arrangement is designed to accommodate various approaching directions, making the connection universal and adaptable to different assembly scenarios.
Solution Approach 2:
The contact pins are arranged in a spatial configuration that accepts approaching directions from multiple dimensions. Rather than requiring precise alignment from a single direction, the contact pins are positioned to engage with the terminal block from various angular and positional approaches, adding dimensional freedom to the assembly process.
Data Source
Figure 1~3
AI summary
Sensor housing comprising a head section with a sensor compartment for receiving a sensor and a connection section adjacent to the head section with a terminal compartment for receiving a terminal block, wherein a plug connection part is arranged in the terminal compartment, the plug connection part has a base body made of an electrically insulating material, at least two contact means made of an electrically conductive material and at least two contact surfaces made of an electrically conductive material, the contact means being designed as contact pins or as contact sockets of a plug connection for establishing an electrical connection, at least two contact means with a contact surface each being in electrical connection, the contact surfaces being arranged spaced apart from each other on a first side surface of the base body.