Sensor Assembly Thermal Decoupling via Segmented Gland Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing sensor assemblies face challenges in efficiently measuring fluid pressure due to high costs and complexities in processing the sensor membrane, handling difficulties during welding, and potential damage from thermal stress and welding debris.
Innovation Solution
A sensor assembly design featuring a tubular gland with a protruding portion for supporting the gland nut, a sealing edge conforming to VCR-Swagelok standards, and a metallic thin film sensor cap with stepped portions for thermal decoupling, allowing for easier assembly and reduced risk of damage during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the gland nut is placed on the gland before welding to the housing, then the assembly can be connected to the process port, but the gland nut moves and rotates during handling making exact welding difficult
Solution Approach 1:
The invention divides the assembly process into two separate stages: first welding the gland to the housing, then separately attaching the gland nut to the gland. This segmentation eliminates the interference between the loose gland nut and the welding operation, allowing precise welding without the gland nut moving or rotating during the process.
2Ease of manufacture
If both the sensor cap and gland are welded to the intermediate member, then the assembly is complete, but thermal stress causes warping of the sensor membrane
Solution Approach 1:
The invention extracts the sensor cap from the welding process by making it a separate component that is not welded to the housing. Instead, the sensor cap is attached to the gland which is welded to the housing. This removes the sensor cap and sensor membrane from the thermal stress zone, preventing warping and measurement failures.
3Ease of manufacture
If welding is performed on both sides of the housing with limited working space, then the assembly is complete, but welding sparks or debris damage the sensor membrane
Solution Approach 1:
The invention extracts the sensor membrane from the welding zone by positioning it on the sensor cap that is not welded to the housing. The welding operations are performed on the gland and housing only, with the sensor membrane isolated from sparks and debris, eliminating the risk of damage while maintaining assembly completion.
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 facilitates easier handling and assembly, reduces thermal stress, and protects the sensor membrane from damage, enabling precise and reliable fluid pressure measurement.
Implementation Method 1
the resulting deformation of the diaphragm 2 can be converted into an electric signal by the sensor chip 4
Implementation Method 2
a sensor chip 4 for converting the amount of distortion of the diaphragm 2
Data Source
AI summary
A sensor assembly consists of a metallic pressure sensor cap welded to a tubular gland, which integrally forms a sealing edge on its one end opposing the pressure sensor cap side, a housing part, which has an opening formed therein such that the gland can penetrate the same, and a gland nut being turnably supported on a projecting portion of the gland for attaching the sealing edge to a process port. A stepped portion of the sensor cap is welded to a stepped portion of the gland, and the housing part is fixed to the outside surface of the gland in a position between the sensor cap and the sealing edge. Here, the sensor cap has an outer diameter, which is smaller than or equal to an outer diameter of the gland, so that the sensor cap being welded to the gland beforehand can be fitted into the opening of the housing part.