Modular Blast Probe With Interchangeable Inserts
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Solution Overview
Problem
Existing blast sensors cannot be accurately tested in their finished, packaged form using traditional pencil and lollipop probes, due to size limitations and difficulties in reproducible alignment, which affects sensing performance and introduces interference with test waves.
Innovation Solution
A modular blast probe with a reusable housing and custom inserts is designed to position and secure blast gauges flush with its outer surface, allowing for accurate testing of finished blast sensors without the need for separate calibration or alignment with traditional probes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional pencil probes are used to test blast sensors, then the sensing elements can be calibrated, but the finished packaged blast sensors cannot be accurately tested due to size limitations and alignment difficulties
Solution Approach 1:
The blast probe is divided into a reusable housing and interchangeable inserts. The inserts are segmented components that can be custom-designed to match specific blast sensor geometries, allowing precise positioning of finished sensors without requiring precision alignment of the entire probe assembly.
Solution Approach 2:
The inserts act as intermediary elements between the reusable probe housing and the blast sensors being tested. These inserts provide the necessary geometric interface to securely hold finished packaged sensors in standardized positions, eliminating alignment difficulties between the probe and sensor.
2Adaptability or versatility
If lollipop probes with larger top surface area are used, then reflected overpressure can be measured, but aligning sensors for testing becomes difficult due to position variance
Solution Approach 1:
By separating the probe into a reusable housing and interchangeable inserts, the system maintains the large top surface area needed for reflected overpressure measurement while using standardized inserts that simplify sensor positioning and alignment procedures.
Solution Approach 2:
The reusable housing serves multiple functions: it provides the structural framework, the wave-shaping exterior surface for accurate blast wave interaction, and the cavity system for holding various inserts. This multi-functionality eliminates the need for separate alignment procedures for each component.
3Measurement precision
If custom inserts are manufactured for each blast sensor model, then accurate testing is achieved, but manufacturing costs increase
Solution Approach 1:
The probe system is segmented into a reusable housing and disposable inserts. This allows the expensive, complex housing to be manufactured once and reused, while only the simple, model-specific inserts need to be manufactured for each sensor type, significantly reducing overall manufacturing costs.
Solution Approach 2:
The inserts are designed to be discarded after use and not recovered. This approach is economically viable because the inserts are simple, model-specific components that can be easily manufactured and replaced, while the complex reusable housing is recovered and reused across multiple testing scenarios.
Data Source
AI summary
Systems and methods are disclosed including a modular blast probe comprising a reusable housing and a custom insert configured to engage and position a top surface of a respective one of a plurality of blast gauges or sensing elements substantially flush with an outer surface of the reusable housing.