Sensor Overload Stop Mechanism for Membrane Protection
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Solution Overview
Problem
Deflectable sensor membranes in force sensors face challenges with inaccurate measurements due to uncontrolled contact points and potential damage from excessive deflection, leading to costly replacements.
Innovation Solution
A sensor assembly with an overload stop mechanism, featuring a center stop and peripheral stop on the sensor membrane, which limits deflection to prevent damage and ensures accurate force measurement by bracing the actuation element at maximum permissible deflection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the sensor membrane is made deflectable to measure force, then measurement capability is improved, but the membrane can deflect past maximum permissible limits causing damage
Solution Approach 1:
The overload stop is pre-positioned on the sensor membrane at a location corresponding to the maximum permissible deflection point. This preliminary placement prevents the membrane from deflecting beyond the safe limit by providing a mechanical stop before damage can occur, thus protecting the membrane while maintaining measurement capability within the safe range.
Solution Approach 2:
The overload stop acts as an intermediary mechanical element between the applied force and the sensor membrane. It intercepts excessive deflection forces before they can damage the membrane, allowing the membrane to function normally for accurate measurements while preventing catastrophic failure under overload conditions.
2Force
If an intermediate element is used to transmit force to the sensor membrane, then force transmission is improved, but the contact point becomes difficult to control leading to inaccurate measurements
Solution Approach 1:
The overload stop serves dual functions: it acts as both the intermediate element for force transmission and its own positioning reference. By being directly disposed on the sensor membrane at the precise maximum deflection location, it eliminates the need for separate positioning mechanisms, ensuring consistent contact points and accurate measurements while maintaining force transmission capability.
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 overload stop mechanism prevents excessive deflection, ensuring accurate force measurement and extending the lifespan of the sensor membrane by limiting the range of deflection and preventing damage from excessive applied forces.
Implementation Method 1
A deflectable sensor membrane can be used as a force sensor. An applied force causes a deflection of the sensor membrane.
Implementation Method 2
The sensor membrane is a piezoresistive device having a resistance that changes in accordance with the deflection.
Data Source
AI summary
A sensor assembly includes a sensor and an overload stop disposed on a surface of the sensor. The sensor has a resilient central region and an outer region surrounding the central region. The overload stop includes a center stop disposed on the central region and a peripheral stop disposed on the outer region.