Coplanar Differential Pressure Transducer With Adaptable Process Interface
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Solution Overview
Problem
Existing differential pressure sensors face challenges in adapting to different customer connections without compromising measurement sensitivity and accuracy, particularly due to the limitations of silicon chips' low overload resistance.
Innovation Solution
A coplanar differential pressure sensor with a measuring unit featuring two process-facing separating diaphragms and a transducer chamber, equipped with a capillary system and insert discs that allow adaptation to various hardware interfaces, including 3051 and IEC standards, while maintaining symmetric design and weld seams outside the separating membranes to prevent interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If overload protection is added to protect the silicon chip, then reliability is improved, but measurement sensitivity and accuracy deteriorate
Solution Approach 1:
The pressure sensing system is segmented into multiple functional diaphragms: a first separating diaphragm for measurement, a second separating diaphragm for overload protection, and a third separating diaphragm for reference pressure. This segmentation allows each diaphragm to perform its specific function independently, enabling overload protection without compromising measurement accuracy of the first diaphragm.
Solution Approach 2:
A second separating diaphragm is introduced as an intermediary element between the process connection and the silicon chip. This intermediate diaphragm absorbs overload pressure through its non-planar deformation, preventing direct transmission of excessive pressure to the silicon chip while allowing normal measurement pressures to pass through to the first separating diaphragm.
2Measurement precision
If the differential pressure sensor is designed for a specific hardware interface, then measurement precision is maintained, but adaptability deteriorates
Solution Approach 1:
The process connection is designed with a universal adapter structure that can accommodate multiple hardware interfaces (3051 interface, IEC interface, and other custom interfaces). The adapter includes a base body with a through-opening and a separable connection element that can be configured for different interface types, allowing the same sensor core to be adapted to various customer connections without compromising measurement precision.
3Ease of manufacture
If weld seams are placed inside the separating membranes for mounting insert discs, then ease of manufacture is improved, but measurement precision deteriorates
Solution Approach 1:
The weld seams for mounting the insert discs are extracted from the area inside the separating membranes and relocated to the outer peripheral region of the process connection. This extraction ensures that welding operations do not interfere with the separating membranes' measurement function, while still providing secure mounting of the insert discs for adapting to different hardware interfaces.
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
Enables seamless adaptation to multiple customer connections, ensuring measurement integrity and protection against overpressure without impairing sensitivity or accuracy, thus safeguarding the pressure-sensitive element.
Implementation Method 1
Two pressures are applied to the separating diaphragms, which are hydraulically transmitted via a corresponding capillary system to a pressure-sensitive measuring element located in the transducer chamber.
Data Source
Figure 1~1a
Figure 2
Figure 2a~3a
AI summary
The invention relates to a coplanar differential pressure transducer (1) comprising a measuring mechanism (2) having two process-facing separating diaphragms (5a, 5b) and a transducer chamber (3). Two pressures (p1, p2) are applied to the separating diaphragms (5a, 5b), said pressures being transmitted hydraulically via a corresponding capillary system (10a, 10b, 11a, 11b) to a pressure-sensitive measuring element (13) which is located in the transducer chamber (3). The measuring mechanism (2) is designed in its process-facing end region as a process connection (21) for a hardware interface (23a, 23b) of a customer connection (24a; 24b). A disc-shaped recess (17) is provided in front of each of the two separating diaphragms (5a, 5b) in the process-facing end face of the main body (9) of the process connection (21). Each of the two disc-shaped recesses (17) are in the form of two circles that intersect in an ellipsoidal structure and have different radii (Ra; Rb). Two insertion discs (19a; 19b) are provided which have an opening (26a; 26b), correspond to the ellipsoidal disc-shaped recesses (17), can be mounted in the ellipsoidal disc-shaped recesses (17), and are designed in such a way that the process connection (21) can be adapted to the hardware interface (23a; 23b) of the customer connection (24a; 24b).