Differential Pressure Sensor Assembly Resistance Pulse Laser Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The production of conventional differential pressure sensors is complex and expensive due to their multi-part construction, which complicates the manufacturing process and increases costs.
Innovation Solution
A simplified method for producing a differential pressure sensor involves a sensor assembly with a rotationally symmetrical outer contour being inserted into a main body with a matching cavity, where it is welded using resistance pulse welding and axial laser welding, potentially incorporating a glass-metal bushing and ceramic base plate, and optionally featuring a circumferential welding collar for stress decoupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a multi-part sensor block construction is used with separate separating membranes and pressure chambers, then the sensor can detect differential pressure accurately, but the production complexity and cost increase significantly
Solution Approach 1:
The patent merges multiple separate components (main body, separating membranes, pressure chambers) into an integrated sensor assembly where the measuring membrane is directly mounted on the main body, eliminating the need for separate pressure transmission lines and reducing the number of individual elements while maintaining differential pressure measurement capability
Solution Approach 2:
The sensor assembly is segmented into functional zones (first pressure reception area, second pressure reception area, measurement area) within a unified structure, allowing independent pressure application to each side while maintaining overall structural integration and simplifying production
2Adaptability or versatility
If multiple individual elements and assemblies are used to construct the differential pressure sensor, then the sensor can perform fill-level and flow measurement functions, but the manufacturing process becomes more difficult and expensive
Solution Approach 1:
The patent combines multiple manufacturing operations into a simplified process where the sensor assembly is produced as a more integrated unit, reducing the number of assembly steps and individual components that need to be manufactured and assembled, thereby lowering production difficulty and cost while maintaining versatility for various measurement applications
3Ease of operation
If conventional multi-part construction is used, then the sensor can be assembled from separate components, but the production time and manufacturing cost increase
Solution Approach 1:
The sensor assembly is pre-assembled and pre-tested as an integrated unit before final installation, with the measuring membrane already mounted and sealed on the main body, eliminating the need for complex final assembly operations and improving overall production efficiency while maintaining ease of installation
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
This approach reduces the complexity and cost of production by integrating the sensor assembly into a main body with fewer components, minimizing measurement accuracy interference and allowing for easier pressure transmission with reduced liquid usage, while maintaining measurement accuracy.
Implementation Method 1
Welding the sensor assembly into the cavity of the main body by means of a resistance pulse welding method in such a way that at least the bearing face of the sensor assembly is welded to the stop face of the main body by a weld seam
Implementation Method 2
Axial laser welding in the opening region of the cavity, so that the main body is peripherally welded to the sensor assembly by means of the welding ring
Data Source
AI summary
A method for producing a differential pressure sensor includes: a) Providing a sensor assembly; b) Providing a main body with a substantially rotationally symmetrical cavity for receiving the sensor assembly; c) Introducing the sensor assembly into the cavity of the main body; d) Welding the sensor assembly into the cavity of the main body by means of a resistance pulse welding method; e) Introducing, for example, by pressing in, a welding ring between the sensor assembly and the cavity of the main body in an opening region of the cavity; and f) Axial laser welding in the opening region of the cavity such that the main body is welded circumferentially to the sensor assembly by means of the welding ring.