Pressure Sensor Membrane Plunger Tolerance Compensation
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Solution Overview
Problem
Existing pressure measurement devices in process and food technology face challenges with complex production processes and signal interference due to non-compressible transmission mediums, particularly in front-flush sensor designs where precise manufacturing and sealing are required.
Innovation Solution
The force transmitting means is designed as a separate part or integral with one membrane, allowing it to be inserted into a hole in the other membrane, simplifying production by compensating tolerances and eliminating the need for sealing elements, ensuring a front-flush design without signal interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If resistance welding is used to connect the two deformation bodies with high precision, then measurement accuracy is improved, but manufacturing complexity increases
Solution Approach 1:
The device is divided into two separate deformation bodies (first and second membranes) that can be manufactured independently with standard tolerances, then connected via a force transmitting means. This segmentation allows each component to be produced separately without requiring the entire assembly to meet extremely tight tolerance requirements, thereby reducing manufacturing complexity while maintaining measurement accuracy.
Solution Approach 2:
A force transmitting means (plunger) is introduced as an intermediary element between the two deformation bodies. This plunger compensates for tolerance variations in the connection area, allowing standard-tolerance components to be assembled reliably. The intermediary absorbs dimensional variations, eliminating the need for high-precision resistance welding while preserving the integrity of the measurement signal.
2Reliability
If front-flush design with non-compressible transmission medium is used, then signal transmission reliability is improved, but production complexity increases
Solution Approach 1:
The force transmitting means is extracted as a separate, removable component that can be inserted into holes in both membranes. This extraction simplifies production by allowing the membranes to be manufactured independently using standard processes, eliminating the need for complex oil filling and sealing operations required in traditional front-flush designs. The separate plunger can be easily installed after the membranes are prepared.
Solution Approach 2:
The force transmitting means is designed with dynamic insertion capability, allowing it to be positioned within the holes of both membranes to compensate for tolerance variations. This dynamic adjustment capability enables reliable assembly without requiring extremely precise pre-machining, thereby reducing production complexity while maintaining the front-flush design's signal transmission reliability.
3Stability of the object's composition
If high precision machining is required for joining and welding, then structural integrity is improved, but manufacturing time increases
Solution Approach 1:
The force transmitting means is designed beforehand to compensate for tolerance variations in the connection holes of the two membranes. By incorporating this compensation mechanism in advance, the design allows standard-tolerance components to be assembled without requiring time-consuming high-precision machining or welding operations, thus maintaining structural integrity while significantly reducing manufacturing time.
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 configuration ensures reliable and accurate pressure measurement with simplified production, eliminating the need for sealing elements and reducing manufacturing complexity while maintaining high measurement accuracy.
Implementation Method 1
the pressure causes a deformation of a deformation body provided for this purpose in the device
Implementation Method 2
The deformation of the first deformation body is transmitted to the second deformation body via a force transmitting means
Implementation Method 3
The deformation of the second deformation body is converted into an electric signal by use of strain gauges
Data Source
AI summary
The disclosure relates to a device for converting a pressure into an electric signal. The device has a first deformation body in the form of a first membrane, via which the pressure can be introduced into the device, and a second deformation body in the form of a second membrane, by means of the deflection of which the applied pressure can be converted into an electric signal. The device has a force transmitting means for transmitting pressure and/or tensile forces from the first deformation body to the second deformation body. Either the force transmitting means is designed as a separate part and the two membranes have a bore into which the force transmitting means is at least partly introduced and in which the force transmitting means is connected to the respective membrane, or the force transmitting means is integrally formed with one of the two membranes and the corresponding other membrane has a bore into which the force transmitting means is at least partly introduced and in which the force transmitting means is connected to said membrane.