Ultrasonic Sensor Direct Injection Nozzle Integration
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Solution Overview
Problem
Ultrasonic sensors used for measuring high-temperature and high-pressure molten liquids in injection molding devices face signal strength reduction and interference due to multiple interfaces, requiring additional signal processing and complex setups.
Innovation Solution
An ultrasonic sensing device with a support body featuring two cover portions and an ultrasonic sensor, where the sensor is securely clamped in a positioning space with a gap between the sensing channel and accommodating space, allowing direct exposure of piezoelectric units for improved signal transmission and noise reduction through a noise-resistant layer and specific channel designs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an additional fixing element is used to mount the ultrasonic sensor at an outer periphery of the injection molding device, then the ultrasonic sensor is protected, but the ultrasonic signal strength is reduced and signal interference is generated due to numerous interfaces
Solution Approach 1:
The ultrasonic sensor is extracted from the conventional mounted position and integrated directly into the injection nozzle, removing the additional fixing element and intermediate structures. This extraction eliminates unnecessary interfaces that cause signal loss while maintaining sensor protection through the integrated design.
Solution Approach 2:
The ultrasonic sensor is nested within the injection nozzle structure, with the sensor housing integrated into the nozzle body. This nesting approach allows the sensor to be protected within the robust nozzle structure while maintaining a direct acoustic path to the molten liquid, avoiding signal loss through intermediate interfaces.
2Reliability
If ultrasonic signals pass through numerous interfaces such as additional fixing element and injection molding device, then the sensor is protected, but the detection precision is reduced due to indirect wave interface
Solution Approach 1:
The detection path is extracted to eliminate intermediate interfaces. The ultrasonic sensor is positioned to transmit signals directly through the injection nozzle wall into the molten liquid, removing the additional fixing element and other intermediate structures that cause signal interference and reduce detection precision.
Solution Approach 2:
The device is segmented into distinct functional zones: the sensor housing integrated into the nozzle, the acoustic coupling interface, and the measurement zone in the molten liquid. This segmentation allows optimization of each zone for its specific function while maintaining a direct acoustic path for high-precision measurement.
3Reliability
If additional signal processing is needed to compensate for signal interference, then sensor protection is maintained, but the device complexity and time consumption increase
Solution Approach 1:
The source of signal interference is extracted and removed by eliminating the additional fixing element and intermediate structures. This prevention approach avoids signal interference at its source, eliminating the need for complex signal processing algorithms and reducing overall system complexity.
Solution Approach 2:
The sensor housing and acoustic coupling structure are preliminarily designed and integrated into the injection nozzle before operation. This preliminary configuration ensures optimal acoustic coupling and direct signal transmission from the start, preventing signal interference rather than requiring post-processing compensation.
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 device provides a robust installation structure with reduced noise and improved signal integrity by minimizing indirect interfaces and enhancing signal strength, facilitating more direct and accurate ultrasonic measurements.
Implementation Method 1
at least one piezoelectric unit located at an end surface of the sensing channel portion
Implementation Method 2
ultrasonic signals transmitted from the ultrasonic sensor need to pass through numerous interfaces
Data Source
AI summary
An ultrasonic sensing device includes a support body and an ultrasonic sensor. The support body includes an accommodating space, and a positioning space at a center of the accommodating space. The ultrasonic sensor includes a body portion in the positioning space, at least one sensing channel portion extending from the body portion and in the accommodating space, at least one piezoelectric unit at one end surface of the sensing channel portion, and a second channel passing through the body portion. An inner diameter of the positioning space is greater than an inner diameter of the accommodating space, and an outer diameter of the sensing channel portion is smaller than the inner diameter of the accommodating space. Thus, a gap is formed between the sensing channel portion and the accommodating space, and the piezoelectric unit is located outside the accommodating space to come into contact with an exterior.