Track Sensor Plug Assembly for Tear-Off Connector Protection
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Solution Overview
Problem
Existing track sensor arrangements face challenges in ensuring durable and reliable connections between wheel sensors and receiving devices, with potential damage to electric connectors when the supply cable is torn off, and maintenance can be complex.
Innovation Solution
A track sensor arrangement featuring a wheel sensor, detachable connection assembly, and track clamp with a slidingly fitted plug body and mounting holder secured by screw or snap-fit connections, incorporating elastic elements and RFID identifiers for enhanced durability and ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the plug body is directly screwed to the support, then the connection is simple, but the electric connectors are vulnerable to damage when the cable is torn off
Solution Approach 1:
The connection assembly is divided into three main segments: the support (fixed to rail), the plug body (containing connectors), and the mounting holder (intermediate component). This segmentation allows the mounting holder to absorb mechanical stresses from cable tension, protecting the connectors in the plug body from direct damage when cables are pulled or torn off.
Solution Approach 2:
The mounting holder acts as an intermediary component between the support and the plug body. It provides a flexible connection point that can deform or fail before the connectors, serving as a protective mediator that shields the valuable electric connectors from mechanical damage during maintenance or accidental cable tension events.
2Stability of the object's composition
If the plug body is rigidly fixed to the support, then the connection is stable, but maintenance and replacement are complex
Solution Approach 1:
The connection system transitions from a rigid fixed connection to a dynamic assembly with multiple degrees of freedom. The plug body slides along the support within defined limits while maintaining electrical connection, and the mounting holder provides adjustable positioning. This dynamic design allows easy disassembly and reassembly during maintenance while preserving operational stability.
Solution Approach 2:
The segmented design with separate support, mounting holder, and plug body components enables independent maintenance of each part. The plug body can be replaced without removing the support or damaging the rail mounting, significantly simplifying repair operations while maintaining stable connection during normal operation.
3Ease of repair
If the plug body is made detachable for easy maintenance, then repair is simplified, but connection reliability may be compromised
Solution Approach 1:
The plug body is nested within the mounting holder structure, which itself is attached to the support. This nested arrangement allows the plug body to be easily extracted for maintenance while the mounting holder and support remain firmly in place. The nested design ensures that reassembly returns the connection to a reliable state, combining ease of repair with maintained reliability.
Solution Approach 2:
The sliding fit mechanism and alignment features enable the plug body to self-align and self-secure when reassembled, reducing the skill level required for maintenance. The design allows field technicians to perform repairs without specialized tools or complex procedures, maintaining connection reliability through simple, repeatable assembly actions.
Data Source
AI summary
A track sensor arrangement consists of a wheel sensor (1), a detachable connection assembly (2) and a track holder (3). The detachable connection assembly (2) consists of a supply cable (4) and a plug (5) provided with an electric plug connection (6B). The track holder (3) consists of a support (7) and of connection elements (8). Inside the body (9) of the plug (5) an assembly compartment (10) is formed. The body (9) of the plug (5) is slidingly fitted on the support (7), wherein on the body (9) of the plug (5) a mounting clamp (11) is slidingly fitted. The mounting clamp (11) is fastened to the support (7) by means of a screw connection (12).