Blind-Mate Spring Pin Connector for Tolerance-Resilient Sensor Coupling
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Solution Overview
Problem
The existing pin/socket interface in sonar sensor assemblies for torpedoes requires high tolerances, is prone to damage, and involves time-consuming and costly manual wiring, with potential for human error leading to improper connections and delays in testing.
Innovation Solution
A sensor assembly using a spring pin connector system with conductive spring pins that are blind-mate interfaced to a circuit board, allowing for positional tolerance variations and reducing the risk of damage and misconnection, while also containing lead wires within the sensor mount structure to simplify installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a pin/socket interface is used for electrical coupling, then reliable electrical contact is achieved, but high tolerances are required and the connection is prone to damage during alignment
Solution Approach 1:
The spring pin is designed with elastic deformation capability, allowing it to dynamically adjust its position during insertion and operation. The spring mechanism enables the pin to deflect and accommodate misalignment between the connector and circuit board, while maintaining reliable electrical contact through continuous spring pressure on the contact pad.
Solution Approach 2:
The spring pin changes its geometric parameters (length, position) through elastic deformation to adapt to tolerance variations. The spring constant and deflection distance are specifically designed to compensate for manufacturing tolerances in the connector and circuit board positioning, ensuring reliable contact without requiring high precision alignment.
2Reliability
If manual wiring is used to connect sensors to the interface board, then electrical connections can be established, but the process is time consuming and costly with potential for human error
Solution Approach 1:
The spring pin connector enables self-aligning and self-connecting functionality. During insertion, the spring pin automatically positions itself and makes electrical contact with the circuit board contact pad without requiring manual wiring operations. The elastic deformation of the spring provides automatic compensation for minor misalignments, ensuring reliable connection.
Solution Approach 2:
The connector integrates multiple functions into a single component: mechanical support for the sensor, electrical connection through the conductive spring pin, and alignment guidance. This merging of functions eliminates the separate manual wiring step and reduces the need for an interface board, significantly reducing assembly time and complexity.
3Ease of operation
If lead wires are extended outside the sensor mount structure for connection, then wiring flexibility is achieved, but noise susceptibility and connection errors increase
Solution Approach 1:
The lead wires are nested within the sensor mount structure rather than extending externally. The spring pin connector is inserted through the mount structure to establish electrical contact, with the lead wires contained inside the sealed environment. This nesting protects the electrical connections from external noise and prevents misconnections.
Solution Approach 2:
The spring pin acts as an intermediary element that establishes electrical connection without requiring external lead wire extensions. The conductive spring pin transmits electrical signals directly from the sensor to the circuit board through the connector body, eliminating the need for vulnerable external wiring while maintaining electrical connectivity.
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
The solution enables reliable and efficient electrical coupling of sensors to electronics assemblies, reducing assembly time and costs, and minimizing noise and misconnections due to its ability to account for positional variations and isolate sensors from the connector system.
Implementation Method 1
a spring operably coupled between the wiring portion and the contact portion, such that the contact portion is axially movable relative to the wiring portion
Data Source
Figure 1A~1B
Figure 1C
Figure 2A
AI summary
A sensor assembly comprises an electronics assembly having a circuit board, a sensor mount structure comprising a first side and a second side, and an aperture formed from the first side towards the second side. The sensor assembly can comprise a sensor supported by the sensor mount structure, such that the sensor is situated, at least partially, in the aperture. The sensor assembly can comprise a spring pin connector coupled to the sensor mount structure, and having a connector body and a pair of conductive spring pins supported by the connector body and electrically coupled to the sensor, and blind-mate interfaced to the circuit board of the electronics assembly, thereby electrically coupling the sensor to the electronics assembly. A sensor array module can include a plurality of sensors and spring pin connectors coupled to a sensor mount structure, which can provide a transponder array of a torpedo.