Inspectable Welds for Differential Pressure Transducer Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current differential pressure transducers fail frequently in high-pressure environments and under cyclic loading due to undetectable defects in welds and seals, leading to measurement inaccuracies and failures.
Innovation Solution
The implementation of inspectable welds in the assembly of differential pressure transducers, allowing for the inspection of critical joints and seals before final assembly, ensuring their integrity and preventing defects from causing failures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional welding methods are used without inspection, then manufacturing complexity is reduced, but reliability deteriorates due to undetectable defects in welds and seals
Solution Approach 1:
The patent applies preliminary action by performing weld inspections before final assembly. The reference tube is welded to the housing with an inspectable weld that can be examined using dye penetrant or magnetic particle inspection methods before the header is attached. This allows defects to be detected and corrected early in the manufacturing process, improving reliability without adding complex inspection equipment to the final device.
2Reliability
If weld inspections are implemented, then reliability is improved, but manufacturing time and complexity increase
Solution Approach 1:
The inspection is performed as a preliminary action during the assembly process, specifically after welding the reference tube to the housing and before attaching the header. This timing allows the weld to be inspected while still accessible, using simple methods like dye penetrant or magnetic particle inspection that do not require specialized equipment or significantly extend manufacturing time.
3Manufacturing precision
If inspectable welds are used, then manufacturing precision is improved, but device complexity increases due to additional assembly steps
Solution Approach 1:
The patent sequences the assembly steps so that the reference tube is welded to the housing first, allowing the weld to be inspected before the header is attached. The header is then welded to the housing in a second step. This preliminary action approach enables precise inspection of the first weld without requiring complex inspection mechanisms, maintaining manufacturing precision while minimizing added complexity.
Data Source
AI summary
Certain implementations of the disclosed technology include a differential pressure transducer and method of assembly. The differential pressure transducer includes: a housing having a first pressure port and a second pressure port; a header welded to the housing; a cap welded to the header; a sensor module disposed in the header and in communication with first pressure port and the second pressure port. The sensor module includes a diaphragm having a first side and a second side. The first side is configured to receive a first pressure by the first pressure port, and the second side is adapted to receive a second pressure by the second pressure port. The differential pressure transducer also includes a reference tube configured to communicate the second pressure from the second pressure port to the diaphragm second side. The reference tube is welded to a portion of the header with an inspectable weld.