Bellows Coupling Differential Pressure Transducer Assembly
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Solution Overview
Problem
Conventional differential pressure transducer assemblies face challenges with stress-related artifacts in output signals due to misalignment of external hard line tubes, complex assembly processes, and limitations in frequency response caused by narrow reference tubes prone to leaking.
Innovation Solution
A differential pressure transducer assembly with an internal bellows coupling between the header and the reference pressure port, which flexes to absorb external stresses and simplifies assembly by eliminating the need for a separate reference tube, enhancing alignment and sealing reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate reference tube with nut and crush ring is used to connect the reference port to the header, then the reference pressure can be routed to the sensor chip, but the assembly becomes complex, time-consuming to assemble, and prone to leaking
Solution Approach 1:
The invention extracts and eliminates the separate reference tube, nut, and crush ring from the assembly. Instead, it integrates the reference pressure routing function directly into the bellows coupling structure, which is welded to both the header and reference port, thereby removing the complex and unreliable separate tube assembly while maintaining the reference pressure routing function.
Solution Approach 2:
The invention merges the reference pressure routing function with the bellows coupling structure. The bellows coupling serves dual purposes: it provides mechanical coupling between the reference port and header while simultaneously serving as the reference pressure channel, eliminating the need for a separate reference tube and its associated fastening components.
2Reliability
If a long, small diameter reference tube is used to route reference pressure, then the reference port can be connected to the header, but the frequency response of the reference pressure measurement is limited
Solution Approach 1:
The invention extracts the reference tube from the system and replaces it with a welded bellows coupling structure that provides a more direct and shorter pressure routing path, thereby improving the frequency response of the reference pressure measurement.
3Measurement precision
If external hard line tubes are connected to the main and reference ports, then pressure can be applied to the sensor element, but misalignment creates torque that imparts stress to the sensor element and creates offset and artifacts in the output signal
Solution Approach 1:
The bellows coupling acts as a flexible element that can accommodate misalignment between external hard line tubes and the transducer ports. Its flexible structure absorbs the torque and stress from misaligned connections, preventing these forces from being transmitted to the sensor element, thereby maintaining measurement precision while providing alignment tolerance.
Solution Approach 2:
The bellows coupling serves as an intermediary element between the external hard line tubes and the sensor element. It mediates the connection by absorbing and isolating the stress and torque from misaligned external tubes, preventing these forces from reaching the sensitive sensor element and degrading measurement accuracy.
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 internal bellows coupling reduces stress-related errors, simplifies assembly, and improves sealing reliability, while maintaining sensitivity to applied pressures and frequency response, thus enhancing the overall reliability and accuracy of the transducer assembly.
Implementation Method 1
The bellows coupling may be configured to flex to reduce or prevent external stress from being applied to one or more of the header and the sensing element
Data Source
AI summary
A differential pressure transducer assembly having an internal bellows coupling configured to improve reliability and ease assembly. The differential pressure transducer assembly includes a header, a sensing element mounted on the header, a first pressure port having a first pressure media channel in communication with a first side of the sensing element, a second pressure port having a second pressure media channel in communication with a second side of the sensing element, and a bellows coupling disposed between the header and the second pressure port. The bellows coupling may be configured to flex during assembly to compensate for tolerance mismatches. The bellows coupling may further reduce or prevent external stress from being applied to one or more of the header and the sensing element.