Capacitive Sensor Spring Holder for Stable Assembly and Calibration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Capacitive sensors face assembly challenges due to spring dislodgment and buckling, leading to defective connections and calibration issues caused by thermal expansion, affecting measurement accuracy.
Innovation Solution
A capacitive sensor design featuring a spring holder with guided coupling and interlocks, along with centring and anti-rotation mechanisms, ensures secure assembly and maintains accurate positioning despite thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If connection springs are arranged initially stretched for assembly, then assembly is simplified, but springs fall out during handling and coil getting caught during compression
Solution Approach 1:
The spring holder is pre-assembled with the connection springs in a stretched state before integration into the sensor. This preliminary preparation allows the springs to be positioned correctly in advance, eliminating the need for complex positioning during final assembly while maintaining their stretched configuration to prevent buckling or coil entanglement during subsequent compression.
2Ease of manufacture
If base plate is made of laminated material for structural integrity, then manufacturing is easier, but thermal expansion causes buckling deformations affecting calibration
Solution Approach 1:
The patent introduces a longitudinal clearance between the base plate and cover casing, changing the spatial parameter of the assembly. This clearance allows the base plate to expand longitudinally during thermal expansion without causing buckling deformations, thereby maintaining the calibration accuracy of the capacitive sensor while preserving the manufacturing simplicity of using laminated material.
3Reliability
If longitudinal clearance is provided between base plate and cover casing to accommodate thermal expansion, then buckling is prevented, but assembly complexity increases
Solution Approach 1:
The patent segments the sensor assembly into distinct components with defined interfaces: the base plate, cover casing, and spring holder assembly. The longitudinal clearance is integrated into this segmented structure, allowing thermal expansion accommodation as a natural feature of the modular design rather than an added complexity. The spring holder with its housings and guided coupling further simplifies the overall assembly while maintaining the necessary clearance.
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
Facilitates easy and safe assembly, prevents spring buckling, and enhances measurement accuracy by maintaining consistent electrode placement and dielectric separation.
Implementation Method 1
the connection springs (4) for connecting the base plate (1) and the terminals (5) of an external connector (3) are arranged in a spring holder (6)... the springs (4) are compressed lengthwise inside the spring holder (6)... the push of the springs ensures electrical communication of the connection
Implementation Method 2
the base plate (1) remains in a floating arrangement that absorbs the dimensional variations of said base plate due to expansions caused by the temperature, at the same time that it maintains the relative position of the base plate inside the cover casing, preventing contact between them
Implementation Method 3
a base plate (1) incorporating an electronic assembly capable of measuring the capacitance between electrodes based on the medium in which they are located, said base plate being arranged inside a cover casing... the level of a liquid can be detected based on the capacitance between electrodes depending on whether they are in the air or immersed in the liquid to be measured
Implementation Method 4
measuring the capacitance between electrodes based on the medium in which they are located... the level of a liquid can be detected based on the capacitance between electrodes depending on whether they are in the air or immersed in the liquid to be measured
Data Source
AI summary
A capacitive sensor comprising a base plate (1) which is housed in a cover casing (2), the base plate (1) being electrically connected to terminals (5) of an external connector (3) by connection springs (4), wherein the connection springs (4) for connecting the base plate (1) to the terminals (5) are arranged in a spring holder (6), which establishes a guided coupling with the base plate (1), and the spring holder (6) with fasteners that establish a first interlock in the base plate (1) in a pre-assembly position with the connection springs (4) at rest, and a second interlock in a final operative fastening position with the connection springs (4) compressed inside the spring holder (6) by pushing the external connector (3) so that it closes on the cover casing (2).