Sensor Housing with Tapered Coupling for Vibration Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Environmental sensors fail in harsh environments due to temperature extremes, radiation, corrosion, and vibration, necessitating ruggedized designs for reliable operation.
Innovation Solution
A multi-part sensor housing with durable materials and innovative coupling mechanisms, including tapered and faceted recesses, frusto-conical projections, and locking collars, to enhance thermal conductivity, vibration resistance, and secure connections, while a shield with an air gap protects electronics from environmental damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sensor housings are used in harsh environments, then the device complexity remains low, but the reliability deteriorates due to temperature extremes, radiation, corrosion, and vibration
Solution Approach 1:
The housing is divided into multiple sections (first housing section, second housing section, head housing section) that can be assembled together. Each section serves specific functions and can be manufactured separately, allowing for optimized design of each component while maintaining overall reliability in harsh environments.
Solution Approach 2:
The housing employs composite construction with different materials for different sections. The use of durable materials with appropriate thermal conductivity, corrosion resistance, and mechanical strength properties creates a composite structure that addresses multiple environmental challenges simultaneously.
2Reliability
If simple coupling mechanisms are used, then the ease of manufacture remains high, but the vibration resistance deteriorates
Solution Approach 1:
The coupling mechanism incorporates a tapered recess with a faceted tip and a frusto-conical projection, using conical and faceted geometric forms. These curved and angled surfaces create friction-based mechanical interlocking that resists vibration forces while maintaining reasonable manufacturability through standard machining operations.
Solution Approach 2:
The coupling elements are designed with pre-configured geometric features (tapered recesses, frusto-conical projections, faceted tips) that automatically align and interlock when housing sections are assembled, providing immediate vibration resistance without requiring additional adjustment or complex fastening procedures.
3Reliability
If the head is directly exposed to the environment, then the device complexity remains low, but the electronics are vulnerable to environmental damage
Solution Approach 1:
A shield is introduced as an intermediary component between the electronics (head) and the harsh external environment. The shield acts as a protective barrier that filters or blocks harmful environmental factors (temperature extremes, radiation, corrosion) while allowing the electronics to function. The air gap between the shield and head provides additional thermal isolation.
4Reliability
If poor thermal conductivity is present, then the temperature extremes have less immediate effect, but the sensor performance deteriorates
Solution Approach 1:
The housing design incorporates regions with different thermal conductivity properties. Certain sections of the housing have higher thermal conductivity to facilitate heat dissipation from the sensor, while other sections (such as near the electronics head) have lower thermal conductivity to protect sensitive components. This localized variation in thermal properties optimizes both sensor performance and electronics protection.
Data Source
AI summary
A sensor and housing suitable for harsh environments includes a central axis and first and second housing sections. The first housing section includes a first fitting including a mating surface orthogonal to the axis and a tapered recess formed in the mating surface and coaxial with the axis. The tapered recess has a decreasing internal dimension at points further from the mating surface and terminates at a faceted recess. The second housing section includes a second fitting having a flange and a frusto-conical projection terminating in a faceted tip. When the first and second housing are coupled, the flange and mating surface are aligned, the frusto-conical projection contacts an interior surface of the first fitting that defines the tapered recess, and the faceted tip seats within the faceted recess. The housing may include a head for housing sensor electronics and a shield that encloses the head and is spaced from the head by an air gap.