Pressure Sensor Force Transmission via Resistance Welding
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Solution Overview
Problem
Existing pressure and force sensors face challenges in manufacturing complexity, temperature-induced signal errors, and reduced accuracy due to the use of compressible transmission media, particularly in applications like process and food technology where a front-flush sensor design is advantageous.
Innovation Solution
A device comprising two deformation bodies connected by resistance-welded force transmission means, where the deformation of a pot-shaped first deformation body is transmitted to a second deformation body with sensor elements, allowing for precise and robust force or pressure measurement without compressible media, and featuring adjustable prestress for enhanced linearity and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a front-flush sensor with oil filling is used to enable direct medium contact, then the sensor can be used in process and food technology applications, but the manufacturing becomes complicated and temperature expansion affects measurement accuracy
Solution Approach 1:
The patent removes the compressible transmission medium (oil) from the force transmission path between the first deformation body and the second deformation body. By directly connecting the two deformation bodies through rigid force transmission means, it extracts the harmful element (compressible medium) that caused manufacturing complexity and measurement errors, while maintaining the front-flush design capability.
Solution Approach 2:
The patent introduces rigid force transmission means as an intermediary element between the first and second deformation bodies. This mediator directly transmits forces without compression, eliminating the need for oil filling while enabling front-flush application. The intermediary structure simplifies manufacturing and eliminates temperature expansion issues.
2Reliability
If compressible transmission medium is used to transmit force from first deformation body to second deformation body, then the force can be transmitted, but measurement accuracy decreases due to compressibility and temperature expansion
Solution Approach 1:
The patent converts the harmful compressibility of transmission media into a benefit by completely eliminating the need for compressible media. The rigid force transmission means provides both force transmission and measurement accuracy simultaneously, turning the previously problematic compressibility issue into a design feature where no compression occurs.
Solution Approach 2:
The patent replaces the hydraulic/mechanical system using compressible oil with a direct rigid mechanical connection. This substitution eliminates the intermediate fluid layer that caused accuracy degradation, allowing direct force transmission from the first to the second deformation body without compression effects.
3Device complexity
If single deformation body is used for force measurement, then the device structure is simple, but both compression and tension forces cannot be effectively transmitted
Solution Approach 1:
The patent divides the force transmission function into two separate deformation bodies (first and second deformation bodies), each optimized for specific functions. The first deformation body handles force application while the second handles signal generation, with rigid force transmission means connecting them. This segmentation enables effective transmission of both compression and tension forces.
Solution Approach 2:
The patent transitions from a single-deformation-body design to a two-body system connected by rigid force transmission means. This dimensional change in the system architecture enables bidirectional force transmission (compression and tension) while maintaining structural simplicity through the direct rigid connection.
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 enables long-term reliable operation with high measurement accuracy, simplified production, and reproducibility, reducing the influence of temperature changes and mechanical stresses on the sensor signal, while allowing for versatile use across different measurement ranges.
Implementation Method 1
The ends are connected to one another by resistance welding
Implementation Method 2
the force or the pressure causes a deformation of a deformation body of the device provided for this purpose
Data Source
Figure 1~2
Figure 3~5
AI summary
The invention relates to a device (1) for converting a force or a pressure into an electrical signal, the device (1) having a first deformation element (10), in particular a first membrane (12), by means of which the force or the pressure can be applied to the device (1), and a second deformation element (20), in particular a second membrane (22), by means of the deflection of which the force or the pressure can be converted into an electrical signal, wherein the first deformation element (10) has a first force transmitting means (14) and the second deformation element (20) has a second force transmitting means (24) for transmitting the force from the first deformation element (10) to the second deformation element (20). The device is characterized in that the first force transmitting means (14) is rigidly connected at the end thereof distant from the first deformation element (10) to the end of the second force transmitting means (24) distant from the second deformation element (20), and in that both compressive forces and tensile force can be transmitted from the first deformation element (10) to the second deformation element (20) by means of the first and second force transmitting means (14, 24). The invention further relates to a method for producing such a device.