Mechanically Calibrated Analog Transducer With Adjustable Spring Preload
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Solution Overview
Problem
Existing position or correlated physical quantity transducers, such as pressure switches in household appliances, face issues with large size, low reliability, complex assembly, high production and assembly costs, and require specialized personnel for calibration, especially when using mechanical or electronic calibration systems.
Innovation Solution
A compact analogue position transducer design featuring a deformable membrane with a threaded stem and bushing system for mechanical calibration, allowing for easy assembly and calibration by non-specialized personnel, utilizing a single spring and adjustable preload, and integrating components through co-moulding for reduced size and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical calibration systems are used, then calibration can be performed, but the device becomes large in size, complex to manufacture and assemble, and difficult to use
Solution Approach 1:
The patent extracts the calibration function from a separate complex mechanical calibration system and integrates it into the transducer body through a compact threaded stem-bushing mechanism. This allows calibration to be performed by simply rotating the bushing relative to the stem, eliminating the need for external calibration equipment and reducing overall device complexity.
Solution Approach 2:
The patent combines the calibration mechanism with the transducer structure by integrating the threaded stem into the membrane assembly and the bushing into the first element. This merging of functions allows the same structural components to serve both transduction and calibration purposes, reducing device size and simplifying manufacturing.
2Measurement precision
If electronic calibration systems with non-volatile memory are used, then calibration accuracy can be improved, but production costs increase and specialized personnel are required
Solution Approach 1:
The patent replaces complex electronic calibration systems with a simple mechanical adjustment mechanism consisting of a threaded bushing and stem. This mechanical substitution eliminates the need for electronic memory units, microprocessors, and specialized calibration equipment, thereby reducing production costs and enabling calibration by non-specialized personnel while maintaining calibration accuracy.
3Ease of operation
If multiple springs are used for membrane operation, then membrane control can be achieved, but the device size increases
Solution Approach 1:
The patent merges the functions of multiple springs into a single spring by integrating the spring directly into the membrane assembly. The spring is positioned to work in conjunction with the threaded stem-bushing mechanism, providing the necessary membrane control force while eliminating the need for separate spring components, thereby reducing device size.
4Measurement precision
If complex assembly procedures are used, then transducer performance can be optimized, but assembly time and costs increase
Solution Approach 1:
The patent segments the transducer into modular components (membrane assembly with threaded stem, bushing, spring, and casing) that can be independently manufactured and then easily assembled. The threaded connection between the bushing and stem provides a simple, repeatable assembly interface that maintains transducer performance while significantly increasing assembly speed and reducing costs.
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 results in a reliable, cost-effective, and easy-to-assemble transducer with reduced electrical consumption, capable of being calibrated by non-trained personnel, achieving high manufacturing and assembly ease while maintaining precise performance.
Implementation Method 1
a deformable membrane sensitive to hydraulic pressure
Implementation Method 2
a deformable membrane sensitive to hydraulic pressure
Implementation Method 3
a threaded stem which extends along said predetermined direction; while the first element is integrally carried by a threaded bushing which meshes with the stem
Implementation Method 4
a spring preloaded and fitted between the casing and the membrane, and means for adjusting the preload of the spring
Implementation Method 5
a second element consisting of an electrical winding forming an inductor, fixed to the casing, is operatively coupled with the first element to provide a signal variable according to the relative position of the first element with respect to the second
Data Source
AI summary
An analogue position transducer, usable for example as a pressure switch in a household appliance, includes a rigid casing accommodating a deformable membrane sensitive to hydraulic pressure, a first element engaged to the membrane so as to be mobile along with at least one portion of membrane in a predetermined direction (A), and a second element fixed to the casing and operatively coupled with the first element to provide a signal variable according to the relative position of the first element with respect to the second element. Between the first element and a portion of the membrane, an element is interposed for varying, along the predetermined direction, the relative position of the first element with respect to the portion of the membrane. The transducer also includes a spring fitted and preloaded between the casing and the membrane, and a further element for adjusting the preload of the spring.