Piezoelectric Force Sensor Spring Electrical Connection
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Solution Overview
Problem
Existing piezoelectric force sensors face challenges in achieving a reliable and reproducible electrical connection between the electrode and contact pin, often resulting in conductivity issues and the need for manual welding, which is labor-intensive and prone to errors due to the miniature design and varying sizes of the sensors.
Innovation Solution
A helical compression spring is electrically conductively connected to the contact pin, detachably connected to the electrode, allowing measurement signals to be routed out of the sensor housing without the need for welding, ensuring a stable and reliable contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spot welding is used to connect electrode and contact pin, then electrical connection is achieved, but manufacturing complexity increases and reliability decreases due to manual operation and contamination risks
Solution Approach 1:
The patent replaces the welding process (thermal/mechanical system) with a mechanical press-fit connection. The contact pin is simply pressed into the electrode holder, eliminating the need for welding equipment, skilled welders, and post-weld inspection processes. This mechanical substitution resolves the contradiction by providing reliable electrical connection without the manufacturing complexity of welding operations.
Solution Approach 2:
The patent introduces an intermediary structure - the electrode holder with a recessed cavity - that mediates between the contact pin and electrode. This holder provides a pre-configured connection interface where the contact pin fits into a precisely formed recess, ensuring proper alignment and electrical contact without requiring manual welding operations. The intermediary structure resolves the contradiction by making the connection process simpler while maintaining reliability.
2Reliability
If manual welding is used for electrical connection, then connection is achieved, but productivity decreases due to labor-intensive process
Solution Approach 1:
The patent replaces manual welding operations with a mechanical press-fit process. The contact pin is inserted and secured through simple pressing or insertion operations that can be easily automated. This eliminates the need for skilled welders, welding equipment setup, and post-weld inspection, thereby dramatically improving productivity while maintaining connection stability through the precise mechanical fit of the recessed cavity design.
3Reliability
If welding is used to connect electrode and contact pin, then electrical connection is established, but manufacturing precision decreases due to heat-affected zones and material deformation
Solution Approach 1:
The patent replaces welding (which introduces heat-affected zones and potential material deformation) with a cold mechanical press-fit connection. The contact pin is inserted into a precisely engineered recess in the electrode holder, ensuring accurate positioning without thermal influence. This mechanical connection method preserves the dimensional accuracy of all components while establishing reliable electrical conductivity, thereby resolving the contradiction between connection reliability and manufacturing precision.
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 solution provides a reliable and reproducible electrical connection that is resistant to mechanical shocks and eliminates the need for welding, enhancing the measuring accuracy and simplifying the production process while preventing contamination and interference.
Implementation Method 1
a helical compression spring (14) made of an electrically conductive material which is permanently connected to the contact pin (131) and detachably connected to the electrode (12)
Implementation Method 2
Two ring-shaped piezoelectric bodies 11, 11' are stacked one above the other in the housing 10
Data Source
Figure 1a~2d
Figure 3a~3c
AI summary
The invention relates to a piezoelectric force sensor (1), comprising a housing (10) having at least one piezoelectric body (11) and an electrode (12) electrically connected to said body (11), wherein a connection device (13), for forwarding measurement signals, having a contact pin (131) is fastened or molded on the housing (10). The contact pin (131) is connected to the electrode (12) in an electrically conductive manner. According to the invention, a helical compression spring (14) is electrically conductively connected to the contact pin (131) as an electrical connection within the piezoelectric force sensor (1). The helical compression spring (14) is removably electrically conductively connected to the electrode (12) in an operative manner such that the contact pin (131) has a spatial clearance from the electrode (12) and measurement signals from the electrode (12) can be extracted from the housing (10) of the piezoelectric force sensor (1) via the helical compression spring (14) and the connected contact pin (131) and can be tapped on the connection device (13).