Modular Differential Pressure Sensor with External Module Attachment
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Solution Overview
Problem
Differential pressure gauges require frequent replacement of sensors and components to measure different pressure ranges, leading to increased production costs and a need for downsizing to enhance measurement accuracy and integration.
Innovation Solution
A physical quantity measuring device with a modular design, where a sensor module is externally attachable to a case body, allowing common use of components and incorporating a sensor substrate with a signal converter and storing circuit to equalize output signals across different measurement ranges, reducing the number of components and enhancing measurement accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the sensor module is integrated inside the case body, then the device structure is compact, but the measurement accuracy deteriorates due to force transfer from the sensor case to the sensor substrate
Solution Approach 1:
The device is divided into separate modules: the sensor module (containing sensor substrate, sensor case, and cover) and the case body. This segmentation allows the sensor module to be externally attached to the case body, preventing force transfer while maintaining a compact overall structure.
Solution Approach 2:
The connection pin serves as an intermediary element between the sensor module and case body. It provides electrical connection while being flexible enough to prevent force transfer, acting as a mediator that decouples mechanical forces while maintaining electrical connectivity.
2Adaptability or versatility
If different sensors are used for different pressure ranges, then the measurement range is extended, but the production cost increases due to the need to replace multiple components
Solution Approach 1:
The case body and connection pin are designed as universal components that can accommodate different sensor modules with various measurement ranges. This universality allows a single case body design to support multiple sensor types, reducing the need to redesign components for each pressure range application.
Solution Approach 2:
By separating the sensor module from the case body, the design allows independent replacement of only the sensor module when changing measurement ranges, rather than replacing the entire device or multiple components. This segmentation reduces manufacturing complexity and cost.
3Volume of moving object
If the base is thinned to reduce device size, then the device is more compact, but force transfer from the port to the base increases, affecting measurement accuracy
Solution Approach 1:
The sensor module is extracted from the case body and externally attached, removing the source of force transfer from the measurement path. This extraction eliminates the harmful force transfer effect while preserving the compact base design.
Solution Approach 2:
The connection pin acts as a flexible intermediary that decouples mechanical forces while maintaining electrical connection, preventing force from the port from being transferred to the sensor substrate through the base.
Data Source
AI summary
A differential pressure sensor includes: a sensor module including: a sensor case including a port through which a target fluid is to be introduced and a base attached with the port; a sensor configured to detect a physical quantity of the target fluid; a sensor substrate attached with the sensor, the sensor substrate having an outer circumferential surface facing an inner circumferential surface of the base; and a cover configured to press the sensor substrate against the base; and a case body including an electric circuit that is housed therein and electrically connectable to the sensor module, the case body having an open end to which the sensor module is externally attached, in which a sensor module clearance is defined between the outer circumferential surface of the sensor substrate and an inner circumferential surface of the sensor case.