Pressure Transducer Segmented Modules Corrosion Resistance
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Solution Overview
Problem
Pressure and differential pressure transducers face challenges in achieving high corrosion resistance while maintaining low manufacturing costs, especially when exposed to corrosive media like acids, alkalis, and seawater.
Innovation Solution
The pressure transducer is designed with a process module made of a corrosion-resistant material and a measuring module made of a less expensive material, with tapered pin-like portions and through-holes to mitigate temperature-related stresses and hysteresis effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the pressure transducer is made entirely from corrosion-resistant material, then corrosion resistance is improved, but manufacturing cost increases significantly
Solution Approach 1:
The pressure transducer is divided into two distinct modules: a process module made of corrosion-resistant material that contacts corrosive media, and a measuring module made of less expensive material that does not contact the media. This segmentation allows each module to be optimized for its specific function and environmental requirements, achieving high corrosion resistance where needed while reducing overall manufacturing costs.
Solution Approach 2:
Different material qualities are applied to different parts of the transducer based on their specific requirements. The process module uses high-quality corrosion-resistant material only where it is needed (in contact with corrosive media), while the measuring module uses standard materials. This local quality approach optimizes resource allocation and reduces unnecessary costs.
2Adaptability or versatility
If two different materials are joined by welding, then manufacturing flexibility is improved, but hysteresis effect occurs due to different coefficients of thermal expansion
Solution Approach 1:
A transition piece made of corrosion-resistant material serves as an intermediary component between the process module and the measuring module. This transition piece has a first connection region that connects to the process module and a second connection region that connects to the measuring module. The intermediary design allows for controlled thermal expansion differences while maintaining connection integrity and minimizing hysteresis effects on measurement accuracy.
3Reliability
If stainless steel with high chromium content is used, then corrosion resistance is improved, but material cost increases
Solution Approach 1:
The transducer is segmented so that expensive high-chromium stainless steel is used only in the process module where corrosion resistance is critical, while the measuring module uses more economical materials. This reduces the total quantity of expensive material required while maintaining adequate corrosion resistance for the application.
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 design achieves high corrosion resistance for the pressure transducer, allowing it to be used with corrosive media without significant impairment, while also reducing manufacturing costs by using less expensive materials for the measuring module.
Implementation Method 1
the pin-like portion has a capillary (12) which is designed to transmit the first pressure of the medium from the process diaphragm to a first surface of the pressure sensor
Implementation Method 2
with tapered pin-like portions and through-holes to mitigate temperature-related stresses and hysteresis effects
Implementation Method 3
mitigate temperature-related stresses and hysteresis effects
Data Source
AI summary
A pressure transducer comprises a process module having a cylindrical main part made of a first material, wherein a pressure-sensitive process diaphragm and an axially disposed through-hole are provided in the main part, and a measuring module having a cylindrical base which is manufactured from a second material that differs from the first material. The base has a pressure sensor and a pin-like-portion, wherein the pin-like portion-projects into the through-hole such that an end portion of the pin-like portion is flush with the end portion of the main part facing the medium. The end portion of the pin-like portion is connected to the end portion of the main part facing the medium, wherein the pin-like portion tapers in the direction of the end portion of the pin-like portion.