Sensor Assembly Segmentation for Thermal Stability
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Solution Overview
Problem
Existing transducer devices with temperature sensors face challenges in long-term stability due to unstable connections between the pipe wall and the sensor, especially under high, low, or rapidly changing temperatures, leading to increased assembly complexity and manual precision demands.
Innovation Solution
A pre-assembled sensor assembly with a rigid carrier element and thermally conductive coupling body, connected to the pipe via resistance welding, simplifies installation and enhances mechanical stability, allowing for prefabrication and reduced tolerance variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a temperature sensor with a coupling body is attached to the pipe wall using thermal conduction, then temperature measurement is achieved, but the connection becomes unstable under high, low, or rapidly changing temperatures leading to long-term reliability issues
Solution Approach 1:
The support element is divided into three segments: a first segment attached to the pipe wall, a second segment carrying the temperature sensor, and a third segment providing mechanical stability. This segmentation allows each segment to be optimized for its specific function while working together to solve the overall connection stability problem under varying temperatures.
Solution Approach 2:
The support element extends in multiple spatial dimensions from the pipe wall, creating a three-dimensional structure that provides both thermal conduction path and mechanical stability. This dimensional approach allows the sensor assembly to maintain stable connection across temperature variations by distributing stresses and thermal paths through multiple spatial directions.
2Reliability
If an additional retaining clip is used to securely fix the temperature sensor to the pipe wall, then connection stability improves, but assembly complexity and manual precision demands increase significantly
Solution Approach 1:
The support element merges multiple functions into a single integrated component: it provides structural support, thermal conduction, mechanical stability, and sensor positioning all in one element. This eliminates the need for separate retaining clips and coupling bodies, simplifying both the device structure and the assembly process while maintaining connection stability.
Solution Approach 2:
The support element serves multiple functions simultaneously: it acts as a mounting bracket, thermal conduction path, mechanical stabilizer, and sensor positioning structure. This multi-functionality reduces the total number of components needed and simplifies assembly while ensuring reliable connection under various temperature conditions.
3Reliability
If the temperature sensor is assembled in-situ on the pipe, then connection stability can be ensured, but manufacturing time and production efficiency decrease
Solution Approach 1:
The temperature sensor and support element are pre-assembled into a complete sensor assembly before installation on the pipe. This preliminary action allows the sensor to be positioned and secured in a single pre-fabricated unit, eliminating the need for complex in-situ assembly operations and significantly improving production efficiency while maintaining connection stability.
Solution Approach 2:
The sensor assembly is designed to be self-contained and self-positioning, with the support element providing inherent alignment and positioning features. This self-service design allows for quick installation without requiring complex alignment procedures or specialized assembly tools, thereby improving productivity while ensuring reliable connection.
4Measurement precision
If manual positioning and fixing of the temperature sensor is performed, then measurement precision can be achieved, but labor intensity and quality control complexity increase
Solution Approach 1:
The support element provides localized positioning features and structural characteristics specifically at the sensor mounting location, ensuring precise sensor positioning relative to the pipe wall. This local quality approach maintains measurement precision by providing dedicated positioning structures where needed, while the rest of the assembly can be manufactured using standard processes.
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 provides a stable and reproducible temperature measurement with reduced drift and improved accuracy, suitable for high-temperature applications and series production, while maintaining mechanical robustness and ease of assembly.
Implementation Method 1
a coupling body (13) that thermally conductively connects the temperature sensor (11) to the support element (12)
Implementation Method 2
connected to the pipe via resistance welding
Data Source
Figure 1a~1b
Figure 2
Figure 3a~3b
AI summary
The sensor assembly according to the invention comprises a temperature sensor (11), a metal support element (2) for holding the temperature sensor, comprising a central segment (12a), an end segment (12b) which adjoins a first end of the central segment, and an end segment (12c) which adjoins a second end of the central segment, said second end being remote from the first end, and a coupling body (13) which couples the temperature sensor to the support element in a thermally conductive manner. The temperature sensor (11) and the coupling body (13) are bonded together and are arranged together on a first surface of the support element. Furthermore, the coupling body (13) is bonded to the support element (12), thereby forming a coupling body-to-support element connection zone. Additionally, in the sensor assembly according to the invention, the lowest degree of flexural rigidity EI12a which the central segment (12a) has at least in the region of the coupling body-to-support element connection zone is greater than the lowest degree of flexural rigidity EI12 which the support element (12) has in total and/or the lowest degree of flexural rigidity EI1 2b which the first end segment (12b) has and/or the lowest degree of flexural rigidity El12c which the second end segment (12c) has.