Two-Wire Electronic Pressure Switch With Millivolt Energy Harvesting

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Mechanical pressure switches in applications like aerospace are susceptible to environmental effects, wear, contamination, and failure modes due to mechanical operation, leading to degradation and inaccurate pressure indications.

Innovation Solution

A two wire pressure indicating switch with an electronic architecture that uses an energy harvester to convert low millivolt levels into higher voltages, eliminating the need for a separate power source and simulating mechanical switch operation with transistors, thereby reducing environmental susceptibility and improving accuracy.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If mechanical pressure switches are used, then pressure indication function is achieved, but reliability deteriorates due to environmental effects, wear, and contamination

Engineering Contradiction:

Improveswitch reliabilityVSAvoidenvironmental susceptibility

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent replaces the mechanical pressure switch with an electronic pressure switch that uses a pressure sensor, signal conditioner, and electronic switching circuitry. This substitution eliminates mechanical wear, friction, and contamination issues while maintaining the pressure indication function, directly resolving the reliability and environmental susceptibility contradiction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If electronic pressure switch is used, then reliability is improved, but device complexity increases due to additional power source requirements

Engineering Contradiction:

Improveswitch reliabilityVSAvoidpower source requirements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The electronic pressure switch is designed to harvest power from the process line itself through the existing two-wire connection. The circuit extracts minimal power during normal operation and accumulates energy during switch closure events, eliminating the need for external power sources or batteries. This self-powered operation reduces device complexity while maintaining improved reliability.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The two-wire connection serves dual functions: it provides both the control signal path and the power source for the electronic circuitry. This multi-functionality eliminates additional wiring and power source components, reducing device complexity while enabling reliable electronic operation.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Measurement precision

If mechanical microswitch is used, then结构简单 is achieved, but measurement precision deteriorates due to contact resistance variations

Engineering Contradiction:

Improvepressure indication accuracyVSAvoidelectronic circuitry

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The mechanical microswitch contact is replaced with an electronic switching circuit that uses transistors or solid-state switches. This substitution eliminates contact resistance variations and mechanical wear that affect measurement precision, while the added electronic circuitry provides signal conditioning and processing capabilities.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Use of energy by moving object

If additional power source is added, then operating voltage is improved, but weight increases

Engineering Contradiction:

Improveoperating voltageVSAvoidpower source weight

Core Design Contradiction:

Use of energy by moving objectVSWeight of moving object

Solution Approach 1:

The electronic pressure switch harvests power from the process line through the existing two-wire connection, eliminating the need for external batteries or power supplies. The circuit accumulates energy during switch closure events and uses it to power the electronic components, achieving adequate operating voltage without adding weight from external power sources.

Inventive Principle:

Principle #25Self-service

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 electronic switch provides reliable, precise pressure indications with increased durability and reduced weight, eliminating the need for additional wires and power sources, and maintaining accuracy over time and environmental conditions.

Implementation Method 1

an energy harvester configured to convert 20 mV when the electronic switch circuit may be in the closed switch condition to an operating voltage between 3.6 Volts and 5 Volts for the electronic switch circuit to operate without an additional power source

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12482619B2Two wire pressure indicating switch with all electronic architecture with millivolt operating supply

Publication Date: 2025.11.25 HYDRA ELECTRIC CO

AI summary

Systems, devices, and methods for a two wire detection circuit powered system comprising: an electronic switch circuit configured to sense a pressure level above or below a predetermined value and indicate an open or closed switch condition, where the electronic switch circuit provides a contact resistance voltage of about 20 mV in the closed switch condition; and an energy harvester configured to convert 20 mV when the electronic switch circuit is in the closed switch condition to an operating voltage between 3.6 Volts and 5 Volts for the electronic switch circuit to operate without an additional power source.