Modular Sensor Housing Segmentation for Fluid Detection
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Solution Overview
Problem
Existing hot-film air-mass meters integrated with pressure and humidity sensors face challenges in design and production, making it difficult to replace or manufacture plug-in sensors with varying functionalities without significant modifications, leading to increased costs and logistical complexities.
Innovation Solution
A sensor device design that separates the electronics space and sensor space within a single housing, allowing for independent assembly and production of plug-in sensors with or without pressure and humidity sensors, using a modular approach that maintains compatibility with existing production lines and tools.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of information
If pressure and humidity sensors are integrated into the hot-film air-mass meter housing, then the sensor can provide additional fluid medium information (pressure and humidity), but the design and production complexity increases significantly
Solution Approach 1:
The sensor device is divided into separate functional modules: a flow sensor module containing the hot-film air-mass meter, and separate pressure and humidity sensors. These modules can be integrated into a single housing but remain independently replaceable and producible, allowing manufacturers to produce different sensor configurations without complete redesign
2Adaptability or versatility
If the sensor housing is designed to accommodate multiple sensor types (flow, pressure, humidity), then external compatibility is maintained, but internal assembly and production processes become more complex
Solution Approach 1:
The housing contains distinct sensor spaces for different sensor types, allowing independent assembly of each sensor module. This modular approach enables manufacturers to assemble different combinations of sensors (flow only, flow plus pressure, flow plus humidity) using the same housing and production line, without requiring complete redesign for each configuration
Solution Approach 2:
The sensor housing is designed as a universal platform that can accommodate various sensor configurations. The same housing structure supports flow sensors, pressure sensors, and humidity sensors, allowing a single production line to manufacture multiple sensor types with different functionalities
3Loss of information
If existing plug-in sensors are replaced with new combined sensors (flow + pressure + humidity), then enhanced measurement capability is achieved, but replacement cost increases due to complete module replacement requirement
Solution Approach 1:
The sensor components are designed as independently replaceable modules within a standardized housing. If a sensor fails or upgrade is needed, individual sensor modules can be replaced without replacing the entire assembly, reducing replacement costs and simplifying maintenance
Solution Approach 2:
Individual sensors (pressure sensor, humidity sensor, or flow sensor) can be extracted and replaced independently from the housing. This extraction capability allows selective replacement of only the necessary component rather than the entire sensor module, reducing replacement costs
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
Enables cost-effective production and easy replacement of sensor devices with or without pressure and humidity sensors, simplifying logistics and maintaining external compatibility, thus reducing production and assembly complexities.
Implementation Method 1
A mass flow and/or volume flow of the fluid medium can be inferred from an asymmetry of the temperature profile detected by the temperature sensors, which is influenced by the flow of the fluid medium
Implementation Method 2
The pressure sensor is set up to be subjected to a pressure of the fluid medium through a pressure-tight connection with the channel area
Implementation Method 3
The humidity sensor is set up to be subjected to moisture in the fluid medium through a moisture-tight connection with the channel area
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
The invention relates to a sensor device (110) for detecting at least one flow property of a fluid medium. The sensor device (110) comprises at least one sensor housing (116) in which at least one electronic module (142) having at least one flow sensor (152) for detecting the flow property is received. The electronic module (142) is at least partially received in at least one electronic chamber (134). At least one pressure sensor (162) and at least one humidity sensor (160) are further received within the sensor housing (116). The pressure sensor (162) and preferably also the humidity sensor (16) are at least partially received in at least one sensor chamber (166) implemented separately from the electronic chamber (134).