Piezoelectric Accelerometer Assembly for Automated Triaxial Sensing

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Solution Overview

Problem

Current accelerometer options fail to meet the requirements for wide-scale implementation in the Industrial Internet of Things (IIoT) due to limitations in size, power consumption, frequency bandwidth, resolution, spectral noise, and configuration, leading to high manufacturing costs and compromised performance.

Innovation Solution

A piezoelectric accelerometer assembly with a rigid circuit board and orthogonal piezoelectric sensing elements, coupled using surface mount technology, along with a charge amplifier circuit, enabling compact, multi-axis measurement and automated manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If piezoelectric sensors are assembled using manual methods, then measurement precision and performance are improved, but productivity and manufacturing cost are worsened

Engineering Contradiction:

Improvevibration measurement accuracyVSAvoidmanufacturing output

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The patent divides the accelerometer assembly into modular components: piezoelectric sensing elements, circuit board modules, and housing sections. This segmentation enables parallel assembly operations and automated manufacturing while maintaining measurement precision through standardized interfaces and controlled assembly processes.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces manual mechanical assembly with automated pick-and-place machines and reflow soldering processes. The mechanical system is substituted with automated equipment that can precisely position and attach piezoelectric elements to circuit boards, thereby increasing productivity without compromising assembly quality.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If MEMS sensors are used for mass production, then productivity and manufacturing cost are improved, but measurement precision and frequency bandwidth are worsened

Engineering Contradiction:

Improvemanufacturing outputVSAvoidfrequency response accuracy

Core Design Contradiction:

ProductivityVSMeasurement precision

Solution Approach 1:

The patent changes the fundamental parameters of the sensing element from MEMS technology to piezoelectric technology. This parameter change enables mass production capabilities similar to MEMS while achieving superior frequency response and measurement precision through the inherent properties of piezoelectric materials.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs composite construction combining piezoelectric ceramic or crystal elements with specialized mounting structures and damping materials. This composite approach enables automated manufacturing while preserving the high-frequency response characteristics of piezoelectric materials, overcoming the limitations of pure MEMS designs.

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If multiple PCB boards and rigid-flex configurations are used, then adaptability and measurement capability are improved, but device complexity and manufacturing cost are worsened

Engineering Contradiction:

Improvemeasurement capabilityVSAvoidassembly structure

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent merges multiple sensing elements and signal processing circuits onto a single rigid circuit board. The triaxial accelerometer integrates three orthogonal piezoelectric sensing elements with their respective signal conditioning circuits on one board, eliminating the need for multiple separate PCB boards and rigid-flex configurations, thereby reducing overall device complexity while maintaining full measurement capability.

Inventive Principle:

Principle #5Merging (Combining)

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 allows for efficient, low-cost production of high-performance accelerometers suitable for industrial applications, overcoming the limitations of MEMS sensors by providing reliable, scalable, and accurate vibration measurement.

Implementation Method 1

a plurality of piezoelectric sensing elements coupled directly on the circuit board in a single plane, wherein at least two of the piezoelectric sensing elements have measurement axes that are orthogonal to each other

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Data Source

PatentUS20250258193A1Method and apparatus for automated production of piezoelectric accelerometers

Publication Date: 2025.08.14 IND CONSULTING AUTOMATION RESEARCH ENGINEERING SRL

AI summary

Various implementations include a piezoelectric accelerometer assembly including a rigid circuit board, a plurality of piezoelectric sensing elements coupled directly on the circuit board in a single plane, wherein at least two of the piezoelectric sensing elements have measurement axes that are orthogonal to each other, and a charge amplifier circuit coupled on the circuit board and electrically coupled to the piezoelectric sensing elements. The piezoelectric sensing elements may include three elements arranged to measure vibration in three orthogonal axes. A conductive shield may be positioned over the sensing elements and amplifier circuit. The assembly enables automated manufacturing and testing of high-performance accelerometers for industrial applications.