Tool-less Gas Sensor Module With Latching And Pin Guide
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Solution Overview
Problem
Existing gas sensor replacement protocols in industrial settings are cumbersome, requiring multiple tools and specific cable configurations, and often necessitate the insertion point to be within the user's field of view, which is inefficient and poses risks in volatile or explosive environments.
Innovation Solution
A tool-less, replaceable gas sensor module with latching features and a pin guide that securely fastens and electrically connects to a housing device without manual cable assembly, allowing for easy insertion and removal without requiring tools or visibility of the insertion point, ensuring intrinsic safety compliance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional gas sensor replacement protocols are used, then electrical connections can be established, but multiple tools and manual cable assembly are required, increasing device complexity and operation time
Solution Approach 1:
The gas sensor system is divided into a removable sensor module and a fixed housing device. The sensor module includes integrated electrical contacts that align with corresponding contacts in the housing device, allowing the sensor to be replaced as a complete unit without manual cable assembly. This segmentation enables the sensor element to be separated from the housing while maintaining reliable electrical connection through pre-configured contact points.
Solution Approach 2:
The sensor module incorporates self-aligning electrical contacts and integrated wiring that automatically connect to the housing device when the module is inserted. The design includes built-in cable management and contact alignment features that eliminate the need for external tools or manual cable assembly during replacement, allowing the system to service itself through the simple act of module insertion.
2Ease of repair
If traditional gas sensor replacement is performed, then sensors can be replaced, but insertion point visibility is required, increasing safety risks in hazardous environments
Solution Approach 1:
The system requires only partial visual attention during replacement - specifically, the user needs to see only the external alignment features and insertion point, not the internal electrical contacts or cable connections. The excessive design features include external alignment guides and visible insertion indicators that eliminate the need to see deep inside the housing device, reducing exposure time to hazardous environments while maintaining ease of replacement.
3Productivity
If tool-less replacement is implemented, then replacement speed increases, but secure fastening and electrical connection must be achieved without manual assembly
Solution Approach 1:
The sensor module design merges the fastening mechanism and electrical connection system into a single integrated unit. The module includes both mechanical retention features (such as clips or latches) and electrical contacts that are permanently attached to the sensor housing. When the module is inserted into the device, both the mechanical fastening and electrical connection occur simultaneously through the same insertion action, eliminating the need for separate assembly steps while ensuring both functions are reliably achieved.
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
A gas sensor module (114) includes a gas sensor (100) configured to provide an electrical indication related to a gas. The gas sensor module (114) also includes an alignment mechanism (208) and a latching feature (204) configured to couple the gas sensor module (114) to a housing device (102). The gas sensor module (114) also includes a pin guide (202) configured to establish an electrical connection between a header (104) of the housing device (102) and the gas sensor (100). In addition, the gas sensor module (114) is configured to be tool-lessly inserted into the housing device (102).