Pressure Fluctuation Sensor With Disk Springs for High-Pressure Sensitivity
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Solution Overview
Problem
Conventional vortex flow meters have compressive strength limitations and sensitivity issues under high pressures and temperatures, particularly in hot steam applications, leading to non-destructive resistance and reduced sensitivity.
Innovation Solution
A sensor design featuring a deformation element with a spring assembly of disk springs to hold the transducer element against the deformation element, maintaining high compressive strength and sensitivity even at high temperatures and pressures, allowing for easy replacement of components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a thin membrane deformation element with high diameter-to-thickness ratio is used to achieve high measurement sensitivity, then the sensitivity to pressure fluctuations is improved, but the compressive strength and resistance to high pressure are reduced
Solution Approach 1:
The sensor is divided into functionally independent segments: a thin-walled deformation element for high sensitivity pressure detection, a separate transducer element for signal generation, and a connection sleeve for mechanical support. This segmentation allows each component to be optimized for its specific function without compromising the others.
Solution Approach 2:
The connection sleeve acts as an intermediary component between the deformation element and the transducer element. It provides mechanical support and force transmission while allowing the deformation element to maintain its thin-walled structure for high sensitivity. The connection sleeve transfers forces from the deformation element to the transducer element without requiring the deformation element itself to be structurally robust.
2Strength
If the sensor components are designed as integrated monolithic structure, then the mechanical strength is improved, but the ease of repair and component replacement is reduced
Solution Approach 1:
The sensor is constructed from multiple separable components (deformation element, transducer element, connection sleeve) that can be independently manufactured, tested, and replaced. The connection sleeve provides a standardized interface that facilitates easy assembly and disassembly of components.
Solution Approach 2:
The connection sleeve serves multiple functions: it provides mechanical support, transmits forces from the deformation element to the transducer element, and enables easy assembly and disassembly of components. This multi-functionality allows the component to achieve both strength and ease of repair.
3Device complexity
If conventional fixed mounting of transducer element is used, then the structural simplicity is maintained, but the ease of repair and component replacement is reduced
Solution Approach 1:
The mounting of the transducer element is made dynamically adjustable rather than fixed. The connection sleeve allows the transducer element to be positioned and secured in a straightforward manner, enabling easy replacement without complex disassembly procedures while maintaining a relatively simple overall structure.
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 sensor maintains high compressive strength and sensitivity without reducing measurement accuracy, enabling reliable operation in extreme conditions and facilitating easy component replacement.
Implementation Method 1
fastening means, which are positioned within the connection sleeve and are connected thereto, for fixing the transducer element in the connection sleeve. In the sensor according to the invention, the fastening means comprise a spring assembly formed by means of at least two disk springs arranged one on top of the other
Implementation Method 2
the deformation element is shaped such that at least one membrane thickness, measured as a minimum thickness of an inner membrane segment delimited by the above-mentioned outer edge segment, is much smaller than a membrane diameter
Data Source
AI summary
The sensor comprises: a flat deformation element including first and second planar surfaces; a sensor lug extending starting from the first surface; a connection sleeve extending from the deformation element; a transducer element, which is arranged within the connection sleeve and contacts the first surface with a contact surface, for generating an electrical sensor signal representing temporally changing movements of the sensor lug and/or temporally changing deformations of the deformation element; and a fastener positioned within the connection sleeve and mechanically connected thereto, for fixing the transducer element in the connection sleeve, wherein the fastener includes a spring assembly with at least two stacked disk springs, which are elastically deformed by exerting a pressing force which holds the transducer element against the deformation element.