Pressure Sensor Connector Assembly Pre-Assembly Testing
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Solution Overview
Problem
Existing pressure sensing devices require assembly before leakage and electronic functional tests can be performed, leading to potential deformation and increased costs due to the need for specialized components and double spring connections.
Innovation Solution
A pressure sensing device design where the connector assembly and main body are produced as separate, rigid parts with a movable spring-biased pogo-pin connection, allowing for pre-assembly testing and reducing the need for non-fixed extensions, enabling serial automated production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If connector assembly and body assembly are attached through standard cables with welding, then electrical connection is established, but leakage test and electronic functional test can only be carried out after assembly is completed
Solution Approach 1:
The device is divided into separate connector assembly and body assembly that can be tested independently before final assembly. The connector assembly includes a connector body with electrical circuit and connection members, while the body assembly includes the main body with sensor housing. This segmentation allows leakage tests and electronic functional tests to be performed on each component separately, eliminating the need to wait until after complete assembly.
Solution Approach 2:
The design enables preliminary testing of connector assembly and body assembly before final assembly. Connection members are designed to establish electrical contact before the complete assembly is finalized, allowing leakage tests and electronic functional tests to be performed in advance. This preliminary action ensures quality control without delaying production.
2Ease of manufacture
If flexible connection cable is bent during assembly, then connection is established, but risk of deformation occurs
Solution Approach 1:
The connection members include spring elements that provide dynamic, compliant electrical connection. The spring-biased pogo pins or similar mechanisms allow for flexible connection while maintaining consistent electrical contact. This dynamic design absorbs bending stresses and prevents deformation of rigid components during assembly and operation.
Solution Approach 2:
The connection members use spring elements that change their physical state based on applied force. The spring mechanism maintains constant electrical contact pressure regardless of bending, ensuring consistent electrical conductivity while accommodating mechanical flexibility during assembly operations.
3Reliability
If specialized ceramic sensor with metal tips is used for soldering or welding, then electrical connection is achieved, but additional elements are required and costs increase
Solution Approach 1:
The electrical connection function is extracted from the ceramic sensor assembly and placed into separate connection members. Instead of integrating metal tips into the ceramic sensor for welding, the connector assembly includes dedicated connection members with electrical contacts that establish connection through mechanical engagement. This extraction eliminates the need for specialized ceramic sensor components and reduces overall complexity.
Solution Approach 2:
The connection members are designed as separate, replaceable components that can be easily manufactured and replaced. Rather than using expensive specialized ceramic sensor components with metal tips, the design employs simpler connection members that achieve reliable electrical connection through mechanical means, reducing both manufacturing cost and complexity.
4Reliability
If double spring connection is required, then electrical contact is maintained, but production costs increase
Solution Approach 1:
The connection members are designed to perform multiple functions with a single component. Each connection member provides both mechanical retention and electrical connection, eliminating the need for separate double spring connections. The spring-biased mechanism integrates both connection and retention functions, reducing component count and manufacturing cost while maintaining reliable electrical contact.
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 design allows for pre-assembly testing, reduces the risk of deformation, and lowers production costs by eliminating the need for specialized components and double spring connections, while ensuring reliable and precise pressure sensing.
Implementation Method 1
a movable spring-biased pogo-pin connection
Implementation Method 2
Pressure sensors used in such sensing device can be a sensor that provides a linear voltage output directly proportional to applied pressure
Data Source
AI summary
A pressure sensing device comprising a body assembly, a connector assembly, an electronic circuit, and a pressure sensor is provided. The pressure sensing device is a compact device allowing for improved assembly. Moreover, the pressure sensing device allows for a leakage test and an electronic circuit control test to be performed before the assembly of the device thereby improving reliability and precision.