Differential Pressure Sensor Integrated into EGR Valve
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Solution Overview
Problem
The existing methods for mounting differential pressure sensors in EGR systems are costly and weight-intensive due to the need for additional brackets, pipes, and connectors, and are prone to incorrect connections and damage.
Innovation Solution
A pressure measurement apparatus where the differential pressure sensor is directly mounted to the EGR valve, with the sensor body extending through the valve and into the gas flow path, eliminating the need for separate connectors and brackets, and allowing a secure interference fit or snap fixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a differential pressure sensor is mounted using brackets and connecting pipes, then the sensor can be securely attached to measure pressure, but the device complexity and weight increase due to additional components
Solution Approach 1:
The sensor body is directly integrated with the EGR valve body, eliminating the need for separate brackets and connecting pipes. The sensor mounting features are incorporated directly into the valve assembly, reducing component count while maintaining secure attachment for accurate pressure measurement
Solution Approach 2:
The EGR valve assembly serves multiple functions: it controls exhaust gas flow and simultaneously houses the differential pressure sensor mounting features. The valve body acts as both a functional component and a sensor mounting structure, reducing the need for separate mounting hardware
2Measurement precision
If brackets and connecting pipes are used to mount the sensor, then the sensor can be positioned for measurement, but the manufacturing cost increases due to additional parts
Solution Approach 1:
The sensor mounting features are integrated directly into the EGR valve body during valve manufacturing, eliminating the need for separate bracket and pipe assemblies. This reduces part count and manufacturing cost while maintaining the capability to accurately measure pressure differential across the valve
3Reliability
If separate connecting pipes and brackets are used, then the sensor can be installed, but the weight of the system increases due to additional components
Solution Approach 1:
The sensor body and mounting features are directly integrated into the EGR valve assembly, eliminating the weight of separate brackets, connecting pipes, and fasteners. The integrated design maintains installation stability while significantly reducing the overall weight of the sensor mounting system
4Measurement precision
If traditional mounting methods with multiple components are used, then the sensor can be attached, but the assembly process becomes more complex and time-consuming
Solution Approach 1:
The sensor mounting features are integrated into the EGR valve body, allowing the sensor to be installed directly with the valve as a single assembly. This eliminates the need for separate installation steps for brackets and connecting pipes, significantly reducing assembly time and complexity while maintaining measurement accuracy
Data Source
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Figure 2
AI summary
Pressure measurement apparatus (101) for an engine, the pressure measurement apparatus (101) comprising: a gas flow path component (105) of a gas flow system of an engine; and a differential pressure sensor (103) having a sensor body (107) defining first and second pressure ports (113A, 113B), wherein the sensor body (107) is configured to cooperate with an opening (115) in a wall of the gas flow path component (105) so that the first pressure ports (113A) terminates inside the gas flow path component (105) and the second pressure port (113B) terminates outside of the gas flow path component (105) in an assembled configuration.