Flangeless Differential Pressure Sensor Module
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Solution Overview
Problem
Existing pressure transmitters require multiple components and potential leak points, increasing installation costs and complexity due to the need for flanges and additional hardware to connect with process fluid sources.
Innovation Solution
A flangeless pressure transmitter design with an integrated primary element and direct connection to process fluid pipes, eliminating the need for external flanges and manifolds by using a unitary construction that includes a sensor module with a built-in process connector and primary element, such as an orifice plate, within the transmitter housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional flange connections are used to connect the transmitter base with process fluid sources, then mechanical securing and sealing are achieved, but device complexity and number of potential leak points increase
Solution Approach 1:
The transmitter base is merged with the process connector into a single unitary structure. The base includes an integrated process fluid flow duct with threaded couplings that directly receive process fluid pipes, eliminating the need for separate flange adapters and unions. This consolidation reduces the number of components and potential leak points while maintaining secure mechanical connection.
Solution Approach 2:
The transmitter base serves multiple functions: it houses the differential pressure sensor, provides structural support, and includes integrated process fluid flow ducts with threaded couplings for direct pipe connection. This multi-functionality eliminates the need for separate flange adapters, reducing overall device complexity while maintaining connection reliability.
2Reliability
If flange adapters and process flanges are used to join process fluid sources with the transmitter, then sealed arrangement is achieved, but installation costs and complexity increase
Solution Approach 1:
The process fluid flow ducts are integrally formed with the transmitter base as a single piece. The threaded couplings are directly molded or machined into the base, eliminating the need for separate flange adapters and reducing installation steps. This integration maintains sealing reliability while significantly reducing installation complexity and cost.
Solution Approach 2:
The transmitter is designed with separate, modular components that snap-fit together: the sensor assembly with isolation diaphragms fits into the base, and process fluid pipes screw directly into the threaded couplings on the base. This segmentation allows for simple, tool-free assembly while maintaining reliable seals at each interface.
3Strength
If multiple components including flanges, bolts, and fasteners are used for connection, then mechanical securing is achieved, but potential leak paths increase
Solution Approach 1:
The transmitter base and process connector are merged into a single unitary structure with integrally formed threaded couplings. This eliminates multiple separate connection interfaces (flange-to-adaptor, adaptor-to-pipe) and reduces potential leak paths to just the direct pipe-to-base threaded connection and the internal diaphragm seals.
Solution Approach 2:
The design extracts and eliminates unnecessary intermediate components (flange adapters, unions, multiple fasteners) from the connection system. Only the essential elements remain: the integrated base with threaded couplings and the internal isolation diaphragms, minimizing potential leak paths while maintaining mechanical securing strength.
4Strength
If bolted connections are used to secure the transmitter base with process fluid sources, then mechanical attachment is achieved, but measurement errors may occur
Solution Approach 1:
The process fluid flow ducts are integrally formed with the transmitter base, creating a rigid, monolithic structure. This integration eliminates flexing and misalignment that can occur with bolted flange connections, ensuring that the isolation diaphragms remain properly positioned and pressure measurements remain accurate without introducing measurement errors.
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 design simplifies the connection process, reduces potential leak paths, lowers costs, and enhances stability and reliability by eliminating the need for bolts and fasteners, while maintaining accurate pressure measurements without the errors associated with traditional bolted connections.
Implementation Method 1
differential pressure sensor for sensing a pressure differential in a process fluid
Implementation Method 2
The hydraulic system comprises one or more hydraulic passageways that are filled with precise amounts of fill fluid, which communicate the process fluid pressure to the capacitive transducer
Implementation Method 3
a primary flow element, such as a venturi tube, orifice plate, pitot tube or flow nozzle, in the process pipe
Data Source
Figure 1
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Figure 3
AI summary
An industrial pressure transmitter (12), for use in industrial process control systems (10), comprises a differential pressure sensor (56) and an integrated process connector (26) connected to the differential pressure sensor (56). A process fluid flow duct (39) extends through the process connector (26) and receives an industrial process fluid. A primary element (64) is positioned in the process fluid flow duct (39) for producing a pressure differential in the process fluid across the primary element (64). The differential pressure sensor (56) is connected to the process fluid flow duct (39) to sense the pressure differential across the primary element (64).