Differential Pressure Sensor Modular Assembly for Easier Automation
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Solution Overview
Problem
Existing differential pressure sensors are difficult to automate partially and are costly to manufacture due to their complex assembly process involving numerous individual components.
Innovation Solution
A modular approach is adopted, where an electronic module and a mechanical module are manufactured independently and then assembled, with the electronic module being inserted into a recess of the mechanical module and joined by welding or gluing, followed by filling with pressure transmission fluid and housing assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If differential pressure sensors are manufactured with numerous individual components integrated sequentially and manually, then the sensor can be assembled with all necessary components, but the manufacturing complexity and cost increase significantly
Solution Approach 1:
The differential pressure sensor is divided into two main modules: an electronic module containing the sensor chip and electronics, and a mechanical module containing the measuring mechanism with separating membranes. These modules are manufactured independently and then assembled together, reducing overall manufacturing complexity while maintaining functional completeness.
Solution Approach 2:
The electronic module and mechanical module are prepared in advance as separate, pre-assembled units. The electronic module is manufactured with the differential pressure sensor chip and electronic components integrated, while the mechanical module is prepared with the measuring mechanism and membranes. This preliminary preparation allows for parallel manufacturing and simplifies the final assembly process.
2Extent of automation
If manual integration of individual components is used, then assembly flexibility is maintained, but automation becomes difficult to implement
Solution Approach 1:
By segmenting the sensor into electronic and mechanical modules that are manufactured separately, each module can be optimized for automated manufacturing. The standardized interfaces between modules enable automated assembly processes while maintaining the flexibility to manufacture different module types independently.
3Device complexity
If a modular design with independently manufactured modules is used, then manufacturing complexity is reduced, but additional joining steps (welding or gluing) are required
Solution Approach 1:
The housing adapter serves as an intermediary component that facilitates the connection between the electronic module and mechanical module. It provides a standardized interface that simplifies the joining process, allowing for consistent welding or gluing operations while maintaining alignment and structural integrity of the assembled sensor.
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 method simplifies and reduces the manufacturing complexity and cost of differential pressure sensors by allowing parallel production of modules and assembly in fewer steps.
Implementation Method 1
welding or gluing the electronic module into the mechanical module, wherein at least the bearing surface is welded or glued to the stop surface
Data Source
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AI summary
The invention relates to a method for producing a differential pressure sensor (1) and to a differential pressure sensor (1) produced by said method. The method comprises at least the following steps: providing an essentially rotation-symmetrical electronic module (2), the electronic module (2) being provided with a main body (3), an outer jacket surface of the main body (3) being produced as a housing adapter (5) that corresponds to a housing (4), an electronics unit (6), and a differential pressure sensor (7); and providing a mechanical module (8), the mechanical module (8) being provided with at least one measuring mechanism (9), wherein a first separating diaphragm (10) and a second operating diaphragm (11) are provided on the measuring mechanism (9), and an essentially rotation-symmetrical recess (12) of the measuring mechanism (9) for receiving the electronic module (2), wherein an inner contour of the recess (12) is matched with an outer contour of the electronic module (2) in such a manner that the electronic module (2) can be introduced into the recess (12).