Modular Pressure Sensor With Spring Contacts for Vibration Resistance
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Solution Overview
Problem
Conventional pressure sensors in gearbox actuators face difficulties in replacement due to soldered connections that are prone to failure under vibrations, leading to serviceability and interchangeability issues, and require intrusive disconnection and reconnection processes.
Innovation Solution
A modular pressure sensor with a spring-based electronic contact junction, featuring three stainless steel springs with gold plating, allows for vibration compensation and easy replacement without soldering, connected via fasteners and a housing made of thermoplastic with glass fiber, enabling operation in extreme temperatures and vibrations up to 2000 Hz.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If soldered connections are used to connect the pressure sensor to the PCB, then electrical connection reliability is improved, but the sensor becomes difficult to replace and serviceability deteriorates
Solution Approach 1:
The pressure sensor is designed as a modular unit with a standardized interface that separates the sensor element from the PCB mounting. This segmentation allows the sensor to be replaced as a complete module without affecting other components, eliminating the need for de-soldering and re-soldering operations while maintaining reliable electrical connections through the standardized interface.
Solution Approach 2:
A standardized interface design is implemented that can accommodate different sensor types while maintaining consistent electrical and mechanical connection protocols. This universal interface enables any sensor conforming to the standard to be interchangeably mounted on the same PCB position, improving both replacement ease and connection reliability through standardized manufacturing processes.
2Stability of the object's composition
If the pressure sensor is rigidly mounted to the PCB, then connection stability is improved, but vulnerability to vibration-induced disconnection increases
Solution Approach 1:
The mounting system incorporates compliant elements and flexible connection mechanisms that allow the sensor to dynamically adapt to vibrations rather than resisting them rigidly. This dynamic mounting approach maintains stable electrical connections while accommodating mechanical vibrations, preventing solder joint fatigue and disconnection.
Solution Approach 2:
The design includes vibration isolation elements and shock-absorbing features in the mounting structure that cushion the sensor and PCB connections against vibration-induced stresses before damage can occur. This beforehand cushioning protects the electrical connections from fatigue and disconnection during vehicle operation.
3Manufacturing precision
If conventional pressure sensors are used with soldered connections, then manufacturing precision is improved, but serviceability and interchangeability deteriorate
Solution Approach 1:
The sensor system is segmented into a replaceable sensor module and a permanent PCB interface. This segmentation shifts the precision requirement from field replacement operations to factory assembly, where automated pick-and-place technology can achieve high precision mounting. The standardized module interface enables easy interchangeability without requiring precision soldering skills at the service level.
Solution Approach 2:
The design replaces traditional mechanical soldering connections with a standardized electrical interface system that uses plug-and-play connectivity. This substitution eliminates the need for thermal processes and manual soldering, allowing sensors to be interchanged through simple mechanical insertion and electrical contact establishment, thereby improving interchangeability while maintaining manufacturing precision through automated assembly.
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
The solution prolongs sensor life to 20,000 operating hours by withstanding vibrations, ensures precise pressure readings, and facilitates easy replacement, maintaining reliability and reducing maintenance complexity.
Implementation Method 1
spring-based electronic contact junction... configured to transfer electronic signals... address the external or environmental factors that influence of the life of the product within the gearbox actuator such as temperature, humidity, pressure, force, and vibration
Data Source
AI summary
A modular pressure sensor (102)—includes a housing (104), a first side (106) of the housing (104) including a pressurized fluid inlet (108), and a second side (110) of the housing (104) being opposite to the first side (106). A spring-based electronic contact junction (140) on the second side (110)—is configured to transfer electronic signals representing pressure of the fluid received at the pressurized fluid inlet (108) to a flex foil or a printed circuit board (PCB). In an aspect, a gearbox actuator (100)—includes the modular pressure sensor (102) and the modular pressure sensor (102) is replaceably mounted onto the gearbox actuator (100).