Track Sensor Plug with Centering Element for Strain Relief
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Solution Overview
Problem
Existing detachable cable connectors for track sensors, such as those using the Amphenol system with bayonet-type connectors, face difficulties in maintenance due to corrosion and contamination, making them hard to detach over time, and risk damage to the sensor when cables are subjected to excessive strain.
Innovation Solution
A device with a plug body and centering element featuring a semi-circular cable conduit, parallel guides, and screw connections, allowing for easy assembly and disassembly while protecting the sensor from strain and enabling external monitoring, with a robust design that prevents sensor damage during maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If detachable bayonet-type connectors are used, then maintenance work is facilitated, but the connectors become difficult to detach over time due to corrosion and contamination
Solution Approach 1:
The invention extracts the cable connector from direct attachment to the sensor housing and places it in a separate, removable position. The connector can be detached from the sensor assembly without removing the entire sensor from the track, enabling easy maintenance while preventing corrosion-related detachment difficulties by allowing periodic replacement of the connector component.
Solution Approach 2:
The sensor assembly is segmented into distinct components: the sensor housing permanently mounted on the track, and the cable connector that can be independently removed. This segmentation allows the connector to be maintained or replaced without affecting the sensor housing, resolving the contradiction between easy maintenance and easy detachment.
2Reliability
If cable connectors are permanently connected to the sensor, then connection reliability is improved, but maintenance work becomes difficult
Solution Approach 1:
The system is divided into a permanently mounted sensor housing and a separately removable cable connector. This segmentation maintains reliable electrical connections through properly designed connector interfaces while enabling easy maintenance by allowing the connector to be independently removed and replaced without disturbing the sensor housing.
Solution Approach 2:
The connector interface is designed to be dynamically changeable between connected and disconnected states. The connector can be firmly connected during operation to ensure reliability, but can be easily disconnected when maintenance is needed, providing dynamic adaptability to different operational requirements.
3Device complexity
If cable connectors are installed directly to the track sensor, then connection simplicity is improved, but sensor damage risk increases when cables are subjected to excessive strain
Solution Approach 1:
The cable connector is extracted from direct attachment to the sensor housing and positioned in a separate, protected location. This extraction creates a protective barrier that isolates the sensor housing from cable strain, preventing force transmission that could damage the sensor while maintaining simple connection through the removable connector interface.
Solution Approach 2:
The removable cable connector acts as an intermediary element between the cable and the sensor housing. It absorbs and isolates mechanical strain from the cable, preventing direct transmission of excessive force to the sensor housing, thereby protecting the sensor while maintaining electrical connection functionality.
Data Source
Figure 1~2
Figure 3~4
Figure 5~8
AI summary
A plug for installation of wired sensor track connectors, including a through body (1) and a plug socket (2) having at least four connectors, wherein the body (1) is provided with a base to be placed in a detachable manner on a centering element (4) configured as an angled profile made of a load-bearing plate and an adjusting plate (6) perpendicular to the load-bearing plate. A frame protrusion (7) is formed on the front wall of the body (1). Parallel starter guides are provided on both sides of the body base. A semi-circular cable conduit is formed in the middle of the load-bearing plate of the centering element (4), wherein parallel resting guides are formed on both sides of the conduit. An adjusting cut-out (11) having a shape adapted to the frame protrusion (7) is provided in the adjusting plate (6).