Weld-In Adapter Structure for Welding Stress Isolation
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Solution Overview
Problem
The installation of weld-in adapters for sensors and actuators in containers is challenging due to thermal stresses during welding, which can lead to local deformations and compromised tightness, especially when integrating them seamlessly with the container wall.
Innovation Solution
The weld-in adapter design features a sealing edge offset from the weld point, with a curved transition area having an angle of inclination to redirect thermal stresses vertically, decoupling the sealing edge from the weld point and enhancing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the weld-in adapter is integrated seamlessly with the container wall, then the tightness and functionality are improved, but thermal stresses during welding cause local deformations and compromise the connection
Solution Approach 1:
The adapter is divided into distinct functional zones: a sealing area with the sealing edge, a transition area with curved structure, and an outer edge area for welding. This segmentation allows each zone to perform its specific function while isolating the sealing area from welding thermal stresses.
Solution Approach 2:
The transition area with curved structure acts as an intermediary element between the sealing area and the outer edge area. It mediates the thermal stresses by providing a gradual transition and stress distribution path, preventing direct transmission of welding stresses to the sealing edge.
2Device complexity
If the sealing edge is positioned close to the weld point for compact design, then the device complexity is reduced, but thermal stresses compromise the sealing tightness
Solution Approach 1:
The curved structure of the transition area introduces a dimensional change in the stress distribution path. By creating a curved transition instead of a straight line, the stress path is extended and redirected, allowing the sealing edge to be positioned closer to the weld point while maintaining sealing integrity through the curved stress distribution.
3Strength
If the adapter structure is made rigid for structural stability, then the strength is improved, but thermal stresses cause local deformations
Solution Approach 1:
Different parts of the adapter have different structural qualities optimized for their specific functions. The outer edge area has a structure optimized for welding and structural support, while the sealing area has a structure optimized for tightness. The transition area has a curved structure that provides both strength and flexibility to accommodate thermal stresses without deformation.
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
This design effectively dissipates mechanical stresses during welding, ensuring a secure and functional connection without impairment, maintaining tightness and metrological accuracy.
Implementation Method 1
the components are melted at the weld point, resulting in extreme thermal stresses on the joining partners. This can lead to the development of significant local stress concentrations
Data Source
Figure 1
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Figure 4~5
AI summary
The invention relates to a weld-in adapter for connecting a sensor (1) or actuator to a container (2) containing a medium, comprising a cylindrical through-opening (4) for receiving the sensor (1) or actuator and a transition region (3a) arranged concentrically around the through-opening (4) and with an outer edge region (3b) that is suitable for welding (6) to the container (2), wherein, at one end, the through-opening (4) has a circumferential sealing edge (5) tapering the through-opening (4), which is suited for being part of a sealing concept for the media-tight connection between the sensor (1) or actuator and the weld-in adapter (3). According to the invention, the sealing edge (5) is offset in parallel by a distance relative to the outer edge region (3b) of the transition region (3a), and the transition region (3a) has a curved structure with an angle of attack α for compensating for this offset.