Modular Pressure Sensor Assembly with Interchangeable Signal Cartridges
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Solution Overview
Problem
Existing sensor assemblies lack versatility and efficiency in formatting pressure signals and accommodating diverse pressure port and electrical connector configurations, limiting their adaptability and accuracy in various applications.
Innovation Solution
The design includes a pressure sensor unit subassembly with a pressure sense element, printed circuit boards for signal formatting, and a modular structure allowing multiple pressure port and electrical connector configurations, enabling flexible signal output formatting and secure mechanical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed sensor assembly design is used, then manufacturing is simpler, but adaptability to different applications is reduced
Solution Approach 1:
The sensor assembly is divided into separable components: a sensor cartridge containing the pressure sense element and a housing with mounting features. This segmentation allows the same housing to accommodate different cartridge types (e.g., different pressure ranges, output formats) by simply replacing the cartridge, thereby improving adaptability without requiring complex reconfiguration of the entire assembly
Solution Approach 2:
The housing is designed with universal mounting features and interfaces that can accommodate multiple types of sensor cartridges. The housing includes standardized pressure port connections, electrical connector interfaces, and mounting hole patterns that work with various cartridge configurations, enabling a single housing design to serve multiple application requirements
2Adaptability or versatility
If multiple signal formats are supported, then versatility across applications improves, but device complexity increases
Solution Approach 1:
Different signal formatting capabilities are implemented as separate, interchangeable cartridges rather than integrating multiple formatting circuits into a single device. Each cartridge is optimized for a specific output format (e.g., voltage, current, digital protocols), and the desired format is selected by installing the appropriate cartridge, thus achieving versatility without increasing the complexity of any individual cartridge design
3Ease of operation
If modular interchangeable components are used, then adaptability and ease of configuration improve, but manufacturing complexity increases
Solution Approach 1:
All necessary calibration, testing, and configuration are performed on the sensor cartridges during their manufacturing process before they are shipped to the customer. This preliminary action ensures that each cartridge is fully functional and calibrated for its specific application, eliminating the need for complex field configuration or calibration procedures and simplifying both manufacturing workflows and end-user deployment
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 approach enhances the adaptability and accuracy of pressure sensor assemblies by allowing different signal formats and configurations, improving their suitability for various applications while maintaining mechanical integrity and accuracy under pressure.
Implementation Method 1
a pressure sense element supported by a first printed circuit board for sensing a pressure presented at the pressure input port and for providing at least one electrical pressure output signal
Data Source
AI summary
The present disclosure relates to sensors including pressure sensors, humidity sensors, flow sensors, etc. In some cases, a sensor unit subassembly for installation in or use with a pressure sensor housing may include at least one pressure sensor signal output terminal supported by a printed circuit board, a pressure input port, and a pressure sense element secured relative to one or more printed circuit boards. The printed circuit board(s) may include circuitry configured to format pressure output signals provided by the pressure sense element into a particularly chosen output format, and may provide the formatted pressure output signal(s) to an attached electrical connector of the pressure sensor housing. In some cases, the sensor unit subassemblies can be mixed with a multitude of different electrical connectors and/or with a multitude of different port connections to from a wide array of pressure sensor assemblies.