Probe Unit Contacting Module Segmentation for Assembly
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Solution Overview
Problem
Existing probe units for capacitive or conductive measurement of process variables in containers face challenges in simple and efficient electrode contacting, particularly in coaxial constructions, which can be time-consuming and require dexterity.
Innovation Solution
A probe unit with a sectionally coaxial construction featuring a probe electrode, a supplemental electrode isolated by insulation, and a flexible circuit board-based contacting module that allows for mechanical contact without soldering or adhesion, using securement means to ensure a lasting conductive connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional cable wiring or flexible circuit boards are used for electrode contacting, then electrical connection is achieved, but the assembly process becomes time-consuming and requires dexterity
Solution Approach 1:
The contacting module is divided into separate components: a first contacting element for the probe electrode and a second contacting element for the supplemental electrode. These segmented elements can be independently positioned and secured, allowing for simpler assembly without requiring complex flexible circuit boards or cable wiring procedures.
Solution Approach 2:
The contacting elements are pre-positioned within the contacting module housing before final assembly. The first contacting element is positioned to contact the probe electrode and the second contacting element is positioned to contact the supplemental electrode, so that during assembly only the securing step is required, significantly reducing assembly time while ensuring reliable electrical connections.
2Volume of moving object
If flexible circuit boards with contact plates are used, then space is saved, but the applying process requires time and dexterity
Solution Approach 1:
Instead of using a single flexible circuit board with multiple contact plates that require precise manual positioning, the contacting module uses separate, simplified contacting elements. Each element is independently designed to contact a specific electrode, making the assembly process easier and less skill-intensive while maintaining compact dimensions.
Solution Approach 2:
The contacting elements are designed as simple, inexpensive components that can be easily replaced if needed. Rather than using complex flexible circuit boards that require specialized handling and positioning skills, the simplified contacting elements can be quickly installed and removed by less skilled operators, improving ease of operation.
3Reliability
If probe electrode and supplemental electrode are contacted through insulation, then electrical isolation is maintained, but connection complexity increases
Solution Approach 1:
The contacting module is segmented into distinct regions: a first contacting element for the probe electrode and a second contacting element for the supplemental electrode. This segmentation allows each element to be independently positioned relative to its respective electrode, simplifying the overall structure while maintaining the necessary electrical isolation through the insulation between the electrodes.
Solution Approach 2:
The contacting module housing serves as an intermediary structure that holds both contacting elements in their respective positions. This housing provides a standardized interface that simplifies the connection process and maintains electrical isolation, reducing the complexity of the overall contacting structure while ensuring reliable electrical connections to both electrodes.
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 quick and reliable electrical contact between electrodes, reducing the risk of defective connections and simplifying the assembly process, while maintaining the coaxial construction's accuracy for capacitive or conductive measurements.
Implementation Method 1
a supplemental electrode (4), which surrounds the probe electrode (3) at least sectionally coaxially and is isolated from the probe electrode (3) by an electrical insulation (5)
Implementation Method 2
Via the capacitance between container wall and the probe electrode and/or between the medium and the probe electrode, the fill level of the medium in the container is determinable.
Data Source
AI summary
A probe unit comprising a probe housing, an at least sectionally rod-shaped, probe electrode, a supplemental electrode, which surrounds the probe electrode at least sectionally coaxially and is isolated from the probe electrode by an electrical insulation. A first securement means, by means of which the supplemental electrode is secured in the probe housing is included, and a contacting module, which is mountable on a rod-shaped section of the probe electrode arranged in the probe housing, and which has a flexible circuit board having at least one first conductive trace for electrically contacting the probe electrode and at least one second conductive trace for electrically contacting the supplemental electrode, and a second securement means for securing the contacting module on the probe electrode are provided.