Spring-Loaded Sensor Mounting Assembly for Misaligned Surface Contact
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Solution Overview
Problem
Existing sensor mounting methods fail to accommodate misalignment between the sensor and the surface it contacts, leading to sub-optimal contact and inaccurate temperature readings.
Innovation Solution
A sensor mounting assembly featuring a thermally conductive sensor body with a flexible polymeric gaiter and compression spring, allowing for angular and vertical movement to ensure optimal surface contact even with misaligned surfaces, combined with a clamp and abutment to limit movement and maintain contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fixed sensor mounting method is used, then the sensor position is stable, but the sensor cannot accommodate misalignment with the surface, resulting in sub-optimal contact
Solution Approach 1:
The sensor mounting assembly incorporates a resilient member (spring) that allows the sensor to dynamically adjust its position and orientation. The spring enables the sensor to move vertically and angularly to accommodate misalignment with the surface, while still maintaining stable contact through its elastic restoring force.
Solution Approach 2:
The mounting assembly changes the physical parameters of the sensor position by allowing vertical displacement and angular rotation. The spring constant and pre-load force are carefully selected to provide the optimal balance between contact pressure and alignment accommodation, adapting to different surface conditions.
2Adaptability or versatility
If the sensor is allowed to move freely to accommodate misalignment, then surface contact is optimized, but the sensor position becomes unstable
Solution Approach 1:
The resilient member provides a dynamic mounting solution where the sensor can move within controlled limits. The spring's elastic properties create a restoring force that stabilizes the sensor position while still allowing sufficient movement to accommodate misalignment, achieving both adaptability and stability simultaneously.
3Ease of manufacture
If a rigid sensor mounting is used, then manufacturing is simple, but the sensor cannot compensate for surface irregularities, leading to inaccurate readings
Solution Approach 1:
The spring-based mounting assembly adds minimal manufacturing complexity while dramatically improving measurement precision. The resilient member allows the sensor to self-adjust to surface irregularities, ensuring optimal thermal contact without requiring complex adjustment mechanisms or precision alignment procedures.
Solution Approach 2:
The sensor mounting assembly is designed to self-adjust to the surface geometry through the spring's elastic deformation. The sensor automatically finds its optimal position and orientation without requiring external adjustment or complex manufacturing processes, achieving high measurement precision with simple manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate temperature sensing by ensuring consistent and improved surface contact regardless of surface alignment, enhancing measurement reliability.
Implementation Method 1
a flexible polymeric gaiter and compression spring, allowing for angular and vertical movement
Implementation Method 2
a thermally conductive sensor body with a flexible polymeric gaiter
Data Source
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AI summary
A sensor assembly (127) having a sensor body (100) with a upper surface (126) to be adjacent an item to aid and detecting the temperature of the item. The sensor assembly (127) include a diaphragm with a disc portion (119) and stem 128 that has the sensor body (100). The disc portion (119) enables movement of the upper surface (126) to adapt to the inclination and location of the surface (111). A spring (101) urges the sensor body (100) into engagement with the surface (111).