Differential Pressure Sensor Overload Diaphragm for One-Sided Pressure Spikes
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Solution Overview
Problem
Existing differential pressure transducers face challenges in providing reliable overload protection, particularly when one-sided pressure drops load the transducer beyond its measuring range, risking damage, and current manufacturing methods for overload diaphragms are complex and incompatible with compact designs.
Innovation Solution
A differential pressure transducer design featuring first and second overload diaphragms with variable material thickness and pre-stressed against mating surfaces, forming variable volume chambers, connected via hydraulic paths to support separating diaphragms and prevent plastic deformation by absorbing excess fluid during overloads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a traditional overload diaphragm with uniform thickness is used, then the structure is simple to manufacture, but it cannot provide adequate protection against one-sided overloads without causing plastic deformation
Solution Approach 1:
The overload diaphragm is designed with radially variable thickness, where the center region has greater thickness for enhanced overload protection capability, while the edge region has reduced thickness to minimize interference with the separating diaphragm's measurement function. This local differentiation allows the diaphragm to provide adequate protection against one-sided overloads without requiring complex manufacturing processes throughout the entire structure.
2Reliability
If the overload diaphragm has large axial stroke to absorb entire separating diaphragm chamber volume, then overload protection is reliable, but the transducer size increases and compactness is compromised
Solution Approach 1:
The variable thickness design concentrates the overload protection function in the center region of the diaphragm, allowing adequate protection with reduced overall axial stroke compared to uniform thickness designs. The thinner edge regions reduce the total volume required while maintaining protection reliability through the thicker center portion that handles the overload absorption.
3Reliability
If the overload diaphragm contour matches the separating diaphragm contour precisely, then support during overload is effective, but manufacturing complexity increases due to complex stamping processes
Solution Approach 1:
The diaphragm bed is designed with a two-region thickness profile that provides effective support to the separating diaphragm during overload conditions. The thicker center region provides robust support where needed, while the thinner edge region simplifies the manufacturing process and reduces interference with the separating diaphragm's normal operation, avoiding the need for complex multi-stage stamping processes.
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 design provides robust overload protection by minimizing plastic deformation and preventing further pressure increase, ensuring the transducer's integrity within its measuring range while maintaining compactness and manufacturing simplicity.
Implementation Method 1
the overload diaphragm is deflected on both sides... sufficiently large hydraulic capacity to absorb the volume of a transfer fluid in a hydraulic path... such that the separating diaphragm of such hydraulic path comes into contact with a diaphragm bed
Implementation Method 2
a first overload diaphragm (150), which is pre-stressed against a mating surface (115) of the measuring element body (110)... a second overload diaphragm (170), which is pre-stressed against a mating surface (115)
Data Source
AI summary
A differential pressure transducer with overload protection includes a measuring element body, two separating diaphragms, two overload diaphragms with radially variable material thickness h(r), a differential pressure transducer for converting a pressure difference into an electrical signal, and two hydraulic paths. The overload diaphragms are connected to the measuring element body to form overload chambers and the separating diaphragms are connected to the measuring element body to form separating diaphragm chambers in which one of the overload diaphragms are enclosed. The separating diaphragm chambers are hydraulically connected to the overload chambers below the other separating diaphragm chamber and to the differential pressure transducer via one of the hydraulic paths, which extend at least in sections through the measuring element body. The overload diaphragms have a base surface, which faces a mating surface in an overload chamber against which the overload diaphragms are pre-stressed in the operative state at pressure equilibrium.