Sensor Adapter Welding for Hygienic Conductivity Sensors
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Solution Overview
Problem
Conductivity sensors with process connections suffer from contamination issues due to unevenness and adhesive degradation, making them unsuitable for hygienic applications.
Innovation Solution
A method involving a sensor adapter and weld connection between the sensor element and process connection, using techniques like ultrasonic welding, to create a secure and contamination-resistant bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used to connect the sensor element to the process connection, then the connection is initially secure, but the adhesive effect attenuates over time leading to contamination
Solution Approach 1:
The patent replaces the chemical adhesive bonding system with a mechanical welding system. The sensor element is welded directly to the process connection using welding technology, eliminating the adhesive layer entirely. This substitution provides a permanent mechanical bond that does not degrade over time like adhesive, thereby resolving the contradiction between initial connection security and long-term durability.
2Ease of manufacture
If multi-part construction with seals is used to connect sensor element and process connection, then assembly is facilitated, but corners and edges create contamination sites
Solution Approach 1:
The patent merges the sensor element and process connection into a unified, seamless structure through welding. By directly welding the sensor element to the process connection, the invention eliminates the multi-part construction with separate seals, corners, and edges. This creates a smooth, continuous surface that prevents contamination sites while maintaining manufacturing feasibility.
3Ease of operation
If sensor element projects beyond process connection with gap, then sensor functionality is maintained, but gap creates potential contamination area
Solution Approach 1:
The patent replaces the adhesive-filled gap structure with a welded joint. The welding process creates a secure mechanical and metallurgical bond between the sensor element and process connection, eliminating the need for an adhesive layer and the associated gap. This maintains sensor functionality while removing the contamination-prone gap region.
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 method ensures a durable and contamination-free connection, enhancing the sensor's suitability for hygienic environments by preventing dirt and medium adherence.
Implementation Method 1
the sensor element is connected to the process connection in the region of the gap by ultrasonic welding
Data Source
AI summary
The present disclosure relates to a method for producing a sensor comprising the steps of: adapting a sensor adapter of the sensor element to a first section of the process connection, introducing the sensor element with the sensor adapter first into the first section of the process connection, so that the sensor element projects beyond the process connection with a second section and the first section of the process connection and the first section of the sensor element form a gap, connecting the sensor element to the process connection by creating a weld connection between the first section of the process connection and the sensor adapter of the sensor element in the region of the gap.