Integrated Gas Spring Sensor Layout for Protected Pressure Sensing
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Solution Overview
Problem
Current gas springs used in industrial processes, particularly in sheet metal stamping, face issues with external sensors that occupy space, are susceptible to damage, and provide unreliable data collection due to exposure, leading to potential gas leaks and inefficiencies.
Innovation Solution
Integration of sensors within the gas spring's cylinder, specifically in the fixing cavity of the base wall, with a sealed measurement duct and a connector for wireless communication, ensuring direct contact with pressure and temperature variables, reducing space occupation, and enhancing protection and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are placed externally on the gas spring, then data collection is possible, but the sensors occupy space in the die and are susceptible to damage
Solution Approach 1:
The sensor is integrated into the gas spring structure itself, specifically housed within a cavity in the base wall of the cylinder. This merging of the sensing function with the gas spring body eliminates the need for separate external sensor mounting, thereby reducing space occupation in the die while simultaneously protecting the sensor from damage during operation.
2Area of stationary object
If sensors are placed inside the gas chamber, then space in the die is saved, but the sensors are exposed to high pressure and temperature conditions
Solution Approach 1:
The gas spring structure is segmented into distinct functional zones: the gas chamber for high-pressure nitrogen storage, the cylinder with its base wall cavity for sensor housing, and the measurement duct connecting them. This segmentation allows the sensor to be positioned within the gas spring assembly (saving die space) while being isolated from the harsh high-pressure and high-temperature environment of the gas chamber through the protective barrier of the base wall cavity and measurement duct interface.
3Ease of manufacture
If external sensors are used for measurement, then installation is simple, but data collection reliability is reduced due to indirect contact with measurement source
Solution Approach 1:
The measurement duct acts as an intermediary element that establishes a direct fluid communication pathway between the gas chamber and the sensor housing cavity. This intermediary structure allows the sensor to indirectly contact the high-pressure nitrogen gas through the duct interface, ensuring reliable measurement data transmission while maintaining the structural integrity and sealing of the gas spring system.
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 configuration improves the gas spring's working capacity, reliability, and data collection efficiency by protecting sensors from damage, reducing gas leaks, and enabling wireless communication without manual intervention, thus enhancing adaptability and cost-effectiveness.
Implementation Method 1
an integrated sensor (2) which is housed in the fixing cavity (4) of the base wall (1d) of the cylinder (1c)... consisting of a sealed meter (2a)
Implementation Method 2
an integrated sensor (2) which is housed in the fixing cavity (4) of the base wall (1d) of the cylinder (1c)... consisting of a sealed meter (2a)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
Gas spring (1) with integrated sensor (2) consisting of a movable piston (1a), a gas chamber (1b) and a cylinder (1c), further consisting of a measurement duct (1e) linked to the gas chamber (1b) and capable of incorporating an integrated sensor (2) which in turn is housed in the fixing cavity (4) of the base wall (1d) of the cylinder (1c) and consisting of the integrated sensor (2) of a sealed meter (2a) and a connector (3) capable of being linked with the communication cable (8).