Sensor Wire Retention via Compression Shielding
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Solution Overview
Problem
Traditional methods for retaining sensor wires in sensor systems, such as LVDT, are inefficient and prone to damage under high vibrational loads, requiring complex wrapping techniques that increase assembly time and risk wire damage.
Innovation Solution
A sensor wire retention device featuring a bobbin tube with coil elements, washers with wire notches, and a return shield element that compresses wires between the washers and shield to reduce strain, along with insulating tape layers and a housing with potting compound to minimize motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional wrapping techniques are used to retain sensor wires, then wire retention is attempted, but assembly time increases and wire damage risk increases
Solution Approach 1:
The wire retention system is segmented into distinct functional components: washers with notches for wire positioning, a return shield element for compression, and a bobbin tube for structural support. This segmentation allows for simplified assembly where each component performs a specific function, reducing the complexity and time of the overall assembly process while maintaining reliable wire retention.
Solution Approach 2:
The return shield element acts as an intermediary component that compresses the wires between itself and the washers. This intermediary mechanism provides efficient wire retention through compression rather than through complex wrapping techniques, thereby reducing assembly time while maintaining retention reliability.
2Reliability
If traditional wrapping techniques are used to retain sensor wires, then wire retention is attempted, but wire damage risk increases
Solution Approach 1:
The invention extracts the wire retention function from the complex wrapping process and implements it through a dedicated mechanical retention system consisting of washers with notches and a return shield element. This extraction eliminates the need for time-consuming wrapping operations that pose wire damage risks, while providing secure wire retention through the specialized washer notches and compression mechanism.
Solution Approach 2:
The return shield element provides beforehand cushioning by compressing and protecting the wires between the washers and the shield itself. This pre-compression protects wires from subsequent vibrational damage and mechanical stress, reducing wire damage risk while ensuring reliable retention.
3Reliability
If wires are retained under high vibrational loads, then sensor operation is maintained, but wire strain increases
Solution Approach 1:
The wire retention system incorporates dynamic strain relief through the compression mechanism. The return shield element applies continuous compressive force on the wires, dynamically counteracting tensile strains induced by vibrational loads. This dynamic balance maintains sensor operation reliability while reducing net wire strain.
Solution Approach 2:
The compression between the return shield element and washers provides beforehand cushioning that absorbs and mitigates vibrational loads before they can cause excessive wire strain. This pre-protection mechanism maintains sensor operation under high vibration while reducing the actual strain experienced by the wires.
Data Source
AI summary
Apparatuses, systems, and associated methods of assembly are described that provide for improved sensor wire retention. An example sensor wire retention device includes a bobbin tube that defines a hollow interior configured to receive a probe assembly inserted therein. The device includes one or more coil elements wrapped around at least a portion of the bobbin tube. One or more washers are attached around the bobbin tube, and each of the one or more washers defines one or more wire notches. The device includes a wire harness of one or more wires, and each of the one or more wires of the wire harness are positioned within the one or more wire notches. The device further includes a return shield element disposed around the wires located within the wire notches of the one or more washers, and the return shield element compresses the one or more wires.