Sensor Mounting Assembly Front-Access Design
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Solution Overview
Problem
Existing environment sensor mounting systems face challenges in securely and conveniently installing and removing sensors from various substrates without damaging them, particularly due to differences in material properties, and often require tools and rear access.
Innovation Solution
A sensor mounting assembly featuring a cylindrical carrier with a locking nut and interlocking elements that allows for easy installation and removal from the front, accommodating different substrate types without tools, and includes a grip structure to prevent slippage and damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If spring arms are used to hold the sensor in the ceiling substrate, then the sensor can be automatically positioned, but the sensor may slip or rattle relative to the hole and the spring force may damage the soft tile substrates
Solution Approach 1:
A carrier component is introduced as an intermediary between the sensor and the ceiling substrate. The carrier includes a body with a cavity that receives the sensor, and a flange that contacts the front surface of the substrate, distributing the mounting force and preventing direct damage to soft substrates while providing stable positioning.
Solution Approach 2:
The mounting system is divided into separate functional components: a carrier component for mounting to the substrate, a sensor component for detection, and an optional locking component for securing. This segmentation allows each component to be optimized for its specific function while working together as a system.
2Reliability
If the sensor is held by springs continuously urging the sensor rearward, then the sensor is secured in the ceiling, but the sensor is not easy to replace from the front of the ceiling
Solution Approach 1:
The locking component features a ratcheting mechanism with teeth that allow the carrier to be advanced and locked in place, but can be easily released by applying force in the opposite direction. This dynamic locking system provides secure mounting during operation while enabling easy replacement when needed.
3Reliability
If an integrated cable is used in the sensor, then the sensor can be powered, but the cable must be disconnected from a remote power box in the plenum requiring access to the plenum for replacement
Solution Approach 1:
The cable connection function is extracted from the sensor unit itself and relocated to the carrier component. The carrier includes a cable access opening that allows the cable to be connected or disconnected from the sensor without removing the sensor from the carrier or accessing the plenum, enabling front-of-ceiling replacement.
4Reliability
If a locking nut with interlocking elements is used to secure the carrier to the substrate, then the carrier is firmly locked and prevents rattling, but the structure becomes more complex
Solution Approach 1:
The locking nut with interlocking teeth serves multiple functions: it secures the carrier to the substrate, provides adjustment capability for different substrate thicknesses, and prevents rotational movement. This multi-functional design consolidates several mounting requirements into a single component, reducing overall system complexity.
Data Source
AI summary
A sensor mounting assembly for installing an environment sensor in a drop-down ceiling or light fixture of a building. The sensor mounting assembly includes a cylindrically-shaped carrier and a locking nut adapted to removably engage the carrier, and to clamp onto the mounting substrate. The carrier further is configured to receive the environment sensor from the front. The carrier and sensor include interlocking features to removably lock the sensor. Both installation and removal of the sensor may be performed from the front of the mounting substrate. Method and kits for mounting the sensor are described.