Sensor Housing Flange Module for Pressure Sealing and Torque Transfer
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Solution Overview
Problem
Existing sensor housings in industrial hydraulics face high production costs and certification efforts due to the need for materials that can withstand both high pressures and torques, necessitating single-piece construction and extensive testing.
Innovation Solution
A flange module with a bearing area and connection element, comprising seals and anti-rotation devices, allows for a pressure-sealed connection between the sensor housing and container, enabling the use of lighter materials for the housing while the flange module absorbs pressure loads, reducing certification needs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If sensor housings are made as single-piece construction to withstand high pressures and torques, then strength and reliability are improved, but production costs and certification efforts increase
Solution Approach 1:
The sensor housing is divided into two separate components: a sensor housing body and a flange module. The flange module contains the bearing area and connection element that directly withstand pressure and torque, while the housing body can be made from less expensive materials. This segmentation allows each component to be optimized independently, reducing overall production costs while maintaining required strength where needed.
Solution Approach 2:
The flange module is constructed from high-strength, pressure-resistant materials specifically at the bearing area and connection element where pressure and torque are applied. The rest of the sensor housing body can use lighter, less expensive materials since they do not directly bear the full pressure load. This local quality approach optimizes material usage and reduces production costs.
2Reliability
If sensor housings are made as single-piece construction to withstand high pressures and torques, then strength and reliability are improved, but certification effort and time increase
Solution Approach 1:
The flange module is designed as a separable component that can be certified independently as a pre-approved pressure-containing element. Once the flange module receives certification, it can be used in multiple sensor housing configurations without requiring recertification of the entire assembly, significantly reducing certification time and effort for different applications.
Solution Approach 2:
The flange module is designed with standardized features (bearing area, connection element, seals, anti-rotation devices) that make it universally applicable to different sensor housing types and container configurations. A single certified flange module design can be used across multiple applications, eliminating the need for separate certification of each housing variant.
3Strength
If high-strength materials are used throughout the sensor housing to withstand torques, then strength is improved, but weight increases
Solution Approach 1:
The sensor housing is segmented into the flange module (containing the connection element and bearing area) and the housing body. Only the flange module requires high-strength materials to withstand torque during tightening and operation. The housing body can use lighter materials since it does not directly transmit torque, significantly reducing overall weight while maintaining torque resistance.
Solution Approach 2:
High-strength materials are applied locally only where torque resistance is critical - specifically in the connection element and bearing area of the flange module. The rest of the housing structure uses lighter materials, optimizing the weight-strength ratio by placing material strength only where mechanically necessary.
Data Source
AI summary
A flange module (10) for a sensor housing (30) has a bearing area and a substantially cylindrical connection element. An opening passes along the longitudinal axis of the connection element through the bearing area and through the connection element. A first seal runs around a lateral surface of the bearing area. A second seal runs on a contact region between the bearing area and the connection element around a lateral area of the connection element. At least one anti-rotation device is arranged on a side of the bearing area facing away from the connection element (12). The sensor housing (30) has an opening in which the bearing area of the flange module (10) is arranged. At least one anti-rotation device of the sensor housing (30) is engaged with at least one anti-rotation device of the flange module (10).