The invention relates to a device for measuring pressure having a base body, and a diaphragm that is arranged on the base body such that the base body and the diaphragm at least partially enclose a cavity, and such that the diaphragm can be exposed to an external pressure to be monitored, wherein the diaphragm is embodied to be deformable in accordance with the external pressure incident on it, such that the magnitude of a spatial dimension of the cavity is correspondingly changed, wherein the device further has a position element, wherein the position element is arranged to move in accordance with the diaphragm, in particular being fixedly attached to the diaphragm.
The measuring and/or monitoring of process pressures and/or the pressure in a container is commonly required in various industrial applications. There are therefore numerous measuring principles employed for this purpose.
In the patent document WO 03/106952 a MEMS (micro electrical mechanical system) pressure sensor is disclosed, which functions on the basis of a capacitive measurement principle. In particular, a change of distance between two electrodes is monitored by means of a capacitive transducer that comprises an inductive coil. A change in the distance between the electrodes due to an incident pressure leads to a change in the resonant frequency of the LC-circuit formed by the electrodes and the inductive coil. The change in the resonant frequency is monitored as it corresponds to the change in distance resulting from the incident pressure, which is to be monitored.
Against this background, the object of the invention is to introduce an improved device for monitoring pressure.
The object is achieved through a device according to the independent claims 1 and 13. Advantageous embodiments of the invention are further defined in the dependent claims and the following description.
The object is therefore achieved with a device for measuring pressure comprising a base body, a diaphragm that is arranged on the base body such that the base body and the diaphragm at least partially enclose a cavity, and such that the diaphragm can be exposed to an external pressure to be monitored, wherein the diaphragm is embodied to be deformable in accordance with the external pressure incident on it, such that the magnitude of a spatial dimension of the cavity is correspondingly changed, further comprising a position element, wherein the position element is arranged to move in accordance with the diaphragm, in particular being fixedly attached to the diaphragm, wherein an inductive planar coil is arranged on and/or in the base body, across the cavity and opposite to the position element, such that the position element and the inductive planar coil are separated in the spatial dimension, wherein the position element serves to influence the inductance of the coil in dependence on the magnitude of the separation in the spatial dimension, and wherein the device measures the external pressure on the basis of the changing inductance of the inductive planar coil.
The planar coil can be arranged in a plane that is essentially perpendicular to the direction of separation between the coil and the position element. The diaphragm can be exposed to the external pressure on a surface of the diaphragm that is facing away from the cavity. That is, the outer surface of the diaphragm can be exposed to the external pressure. The cavity can be filled with a compressible fluid. The cavity can also be exposed to an ambient pressure such that the external pressure is measured with respect to the ambient pressure. In this case, the device for measuring pressure can be referred to as a gauge pressure sensor. The external pressure can be a process pressure of a process in a container or pipe that is to be measured and/or monitored.
A device which is used to measure pressure on the basis of a changing inductance of a planar coil can advantageously resolve a movement of the position element in the micrometer range, in particular to within 10 micrometers. Furthermore, the such a device is robust in the face of adverse conditions confronted by sensor electronics, such as dust, humidity, moisture, vibration, pressure, fluctuation of day/night temperature and has a broad operating temperature range (−40° C. to +90° C.). In particular, such a noncontact type of inductive pressure sensor can be advantageous in such applications over sensors based on resistive or capacitive principles.
By modeling a planar inductive coil with a program run on a computing machine, it is possible to estimate, i.e. calculate, i.e. predict the change of such a coil's inductance in dependence on the change of distance between the coil and the position element such as, for example, a copper activator element arranged across from said planar coil. Such an estimation/calculation/prediction can be used in the evaluation of a signal from a real coil. For example, the relationship between a change in pressure and a change in the inductance can be modeled and stored in a data-processing unit and/or an evaluation unit, such that the signal from the coil can serve as an input; making possible a reverse estimation/calculation/prediction of the incident pressure.
In an embodiment of the inventive device, the device further comprises a processing unit, wherein the processing unit comprises a signal generating unit that serves to generate an electrical signal, and in that the signal generating unit is electrically connected to the coil, such that the electrical input signal can be transmitted to the coil.
The pressure sensing device can comprise, for example, a signal generating unit for generating a sine wave signal comprising an amplifier. The signal generating unit can also be embodied to generate a square wave input signal for the coil.
In an embodiment of the inventive device the processing unit comprises an evaluation unit, wherein the evaluation unit has a signal receiving interface, which is electrically connected to the coil and the signal generating unit, wherein the evaluation unit serves to determine the external pressure on the basis of an electrical output signal output from the coil to the signal receiving interface.
As with the input signal, the output signal can be for example a sine wave or a square wave, which can generally be understood as a summation of sine waves. The signal receiving interface should therefore be embodied to receive and an analog signal having one of these forms.
The processing unit can be located locally, i.e. within the housing of the device, or remotely. In the case where the processing unit is located remotely, the housing can comprise electrical contacts, which are connected to input and output contacts leading to the planar coil. A remotely located processing unit enables the use of low cost components, since certain durability requirements can be eliminated or lowered. For example, components suitable for use in a restricted temperature range may be used in a remotely located processing unit.
In an embodiment of the inventive device the processing unit comprises a sampling module, in particular an analog to digital converter, which serves to sample the output signal from the coil. An analog output signal from the coil can therefore be converted to digital form, greatly reducing the difficulty of mathematical processing the signal.
In an embodiment of the inventive device the position element comprises copper. When the copper activator (i.e. position) element is brought very close to the planar coil the coupling factor increases from 0 to some moderate value (e.g., 0.5 to 0.6) and thereby, the inductance of planar coil is reduced approximately by 40% to 50% of its nominal value. When the position/activator element moves away further from the concerned planar coil the coupling factor is reduced to zero value and therefore, inductance value of the planar coil goes back to its nominal value. The change of planar coil's inductance value is suitably converted to a corresponding voltage signal and the location of the position element is estimated. The aforementioned physical phenomenon can also be explained alternatively as follows. When an alternating current flows into the planar coil it produces a varying magnetic flux in the surrounding air core. The varying magnetic field impinging on a “shorted secondary winding” i.e. the copper activator/position element induces further a varying voltage and current in accordance with Faraday's electromagnetism law. The induced current in the copper activator/position element, termed as eddy current, further opposes the varying magnetic flux generation in accordance with Lenz's law and thus also opposing the current flow into the planar coil by giving rise to the lower coil inductance value. The higher the frequency of primary current, larger is the eddy current effect in the copper plate. This, in turn, reduces the coil inductance of the inductive sensor.
In an embodiment of the inventive device the position element comprises an electrically isolating and ferromagnetic material, in particular Nickel-Zinc-Ferrite and/or Manganese-Zinc-Ferrite. The position element can comprise a highly permeable and electrically poorly conducting material. Examples of such materials are MP1040-200, MP1040-100 from Laird-Technologies or WE354006 of the WE-FSFS-354—Material group, which can be acquired from the company Würth-Elektronik in the year 2017. These materials are suitable for shielding from 13.56 MHz-RFID transponders. The material WE354006 can have a block form, with a respective width and length of 60 mm, and a thickness of 0.3 mm, which can be sliced in to required size. The complex permeability at a frequency range around 13.56 MHz is μ′=150, μ″=90, where the relative permeability is defined as μr=μ′−jμ″ or relatedly μr=B/B0=√(μ′2+μ″2)=ca. 175. Here, B is the magnetic flux density in the ferrite material, and B0 is the magnetic flux density in vacuum or air.
In contrast to a conventional arrangement in which the position element comprises an electrically conductive metal and which reduces the inductance of the coil by eddy current formation, the ferromagnetic and electrically insulating material can increase the inductance of the coil. As a result, a useful signal can be increased and a signal-to-noise ratio (SNR) can be increased. A multi-stage amplification of the useful signal can thereby be dispensed with. By increasing the inductance, the basic inductance of the coil can be relatively small without the influence of the positioning element. The coil can thus have reduced dimensions. The inductance of the coil is usually determined by exciting the coil by means of an electrical voltage at a frequency in the Megahertz MHz range. This frequency can be significantly lower than in arrangements with a metallic position element. The frequency may, for example, be approximately 12 MHz and thereby be several orders of magnitude less than in arrangements with a conducting position element. A circuit for providing this frequency and the evaluation device can be implemented more simply or with less expensive components because of the reduced frequency. Switching elements for connecting the coil to the frequency can also be more cost-effective. Electromagnetic compatibility of the device may also be improved.
The inductance increase through the position element can be more pronounced than the attenuation by a metallic position element so that the tolerances of the elements of the device for inductive position determination can be selected to be larger. As a result, more cost-effective components can be used and calibration of the device within the scope of production can be dispensed with.
Additionally, the use of a non-conducting, ferromagnetic position element can be used in pressure sensing applications where a metallic positioning element such as copper where the positioning element is exposed to oxidizing or etching agents.
In an embodiment of the inventive device the diaphragm is formed from a ceramic material. Ceramic diaphragms are exceptionally temperature resistant and can be used in applications where a process to be monitored is at a high temperature, for example above 100 degrees Celsius.
In an alternative embodiment of the inventive device the diaphragm is formed from a metal, in particular a thin sheet of metal, and/or is coated with a paint and/or Teflon i.e. PTFE.
The diaphragm can also be formed from a synthetic polymer based material.
In an embodiment of the inventive device the position element is essentially flat and has a rhombus or hexagonal shape. It is also possible for the position element to have a rectangular, circular or other geometrical shape.
Flat in the sense of the present invention describes an object that has a height which is at the most a 5th of the width and/or breadth of the object. In a conducting position element, the eddy current formation that influences the coil inductance takes place at or near the surface to the position element. Therefore, the use of additional material to increase the height of the position element generally has no additional advantage regarding the effect provided. Since copper in particular can be expensive, a flat form provides the best cost benefit ratio, since this is also the most effective form.
In an embodiment of the inventive device the coil is embodied as a printed conducting pathway on a substrate, in particular on a printed circuit board. The planar coil is fabricated directly on the PCB so that the coil's inductance is influenced by the eddy current damping effect due to the position element. Due to the limited space on the PCB often such coils have a smaller size and fewer turns, e.g. 8-9 turns. Again, a small coil size and fewer of turns will produce a smaller amount of inductance which may be insufficient for a reliable position sensing. Therefore, inductive position sensing method often uses the multi-layer planar coils with a copper, brass or aluminum metal plate as an activator (i.e. position) element approximately 0.15 to 0.45 mm and/or even as close as 0.7 mm over the coil, wherein the transducer generates a coil voltage/inductance that changes along with moving distance under the eddy current damping effects at higher frequencies.
Planar coils of different geometrical shapes (square, rectangular, trapezoidal, circular or even elliptical) as well as position elements of the aforementioned geometrical shapes may be used in the inventive device.
In an embodiment of the inventive device the coil comprises a first layer and a second layer, wherein the first and second layers are essentially aligned.
The orientation and position of a layer of a planar coil can be defined by an axis running through the center of an area covered by the layer of the coil in the plane of the coil and extending essentially perpendicular to the plane in which the layer of the coil is arranged. When these layers of the coil are aligned, these axes are essentially identical to each other. However, the planes in which the coils are arranged can be separated by a certain distance. This can advantageously result in a larger coil inductance. For example, the layers could be fabricated on two opposite surfaces of a printed circuit board.
The inductance of a multilayer coil in the inventive device has a greater dependence on the separation between the coil and the position element and requires less space on a printed circuit board (PCB), than a single layer coil with the same inductance dependence would require.
In an embodiment of the inventive device the coil is embodied to have only a single layer. Generally, it is difficult and expensive to automate the quality control of multi-layer planar coils. Single layer coils on the other hand can be visually inspected, for example in an automated scanning process, since the entire structure of the coil is present on one side of a substrate, such as a printed circuit board. This can reduce the costs and increase the speed of producing reliably fabricated coils.
The object is further achieved through a method for measuring pressure with a device having a base body and a diaphragm that is arranged on the base body such that the base body and the diaphragm at least partially enclose a cavity, and wherein the diaphragm is embodied to be deformable in accordance with the external pressure incident on it, such that the magnitude of a spatial dimension of the cavity is correspondingly changed, and wherein the device comprises a position element, wherein the position element is arranged to move in accordance with the diaphragm, in particular being fixedly attached to the diaphragm, wherein an inductive planar coil is arranged on and/or in the base body, across the cavity and opposite to the position element, such that the position element and the inductive planar coil are separated in the spatial dimension, wherein the position element serves to influence the inductance of the coil in dependence on the magnitude of the separation in the spatial dimension,
comprising the steps of
exposing the diaphragm to an external pressure to be monitored, and
measuring the external pressure on the basis of the changing inductance of the inductive planar coil.
The invention also relates to a differential pressure flow meter for measuring the flow of a fluid, in particular a liquid, through a pipe comprising at least one device for measuring pressure having a base body and a diaphragm that is arranged on the base body such that the base body and the diaphragm at least partially enclose a cavity, and wherein the diaphragm is embodied to be deformable in accordance with the external pressure incident on it, such that the magnitude of a spatial dimension of the cavity is correspondingly changed, and wherein the device comprises a position element, wherein the position element is arranged to move in accordance with the diaphragm, in particular being fixedly attached to the diaphragm, wherein an inductive planar coil is arranged on and/or in the base body, across the cavity and opposite to the position element, such that the position element and the inductive planar coil are separated in the spatial dimension, wherein the position element serves to influence the inductance of the coil in dependence on the magnitude of the separation in the spatial dimension and wherein the device is embodied to determine the external pressure on the basis of the changing inductance of the inductive planar coil.
The invention further relates to differential pressure level meter for measuring the level of a fluid, in particular a liquid, in a container comprising at least one device for measuring pressure having a base body and a diaphragm that is arranged on the base body such that the base body and the diaphragm at least partially enclose a cavity, and wherein the diaphragm is embodied to be deformable in accordance with the external pressure incident on it, such that the magnitude of a spatial dimension of the cavity is correspondingly changed, and wherein the device comprises a position element, wherein the position element is arranged to move in accordance with the diaphragm, in particular being fixedly attached to the diaphragm, wherein an inductive planar coil is arranged on and/or in the base body, across the cavity and opposite to the position element, such that the position element and the inductive planar coil are separated in the spatial dimension, wherein the position element serves to influence the inductance of the coil in dependence on the magnitude of the separation in the spatial dimension and wherein the device is embodied to determine the external pressure on the basis of the changing inductance of the inductive planar coil.
The invention will next be described with reference to the following figures. They show:
The processing unit comprises a signal generating unit 17 for transmitting an electric signal to the planar coil 11. A receiving interface 19 is provided to receive and sample the electrical signal from the planar coil 11. The relative difference between the input and output signals of the coil 11 is influenced by the inductance H of the coil 11.
The processing unit 13 further comprises a communications interface 21 for exchanging information with external devices. The interface 21 is depicted as a communications line having two conductive pathways. The communications interface 21 can however also be a single conducting pathway, or even a wireless communications interface 21.
A position element 9 is fixed to the diaphragm 5. The position element 9 is situated across the cavity 7 from the planar coil 11 and is separated from the planar coil 11 by a distance d. When a pressure is incident on the diaphragm 5, the diaphragm 5 can deform such that the distance d changes. The change in the distance d influences the inductance H of the planar coil 11 due to properties of the position element 9. The position element 9 can for example be conductive, such that eddy currents form due to the changing magnetic field produced by the coil 11 when a signal is input from the processing device. These eddy currents in turn contribute to the magnetic field and can contribute to a change in the electric potential within the metal conductive pathway of the coil 11, thereby influencing the input signal. This influence, or the result thereof, can be monitored in the processing unit 13 by examining the output signal of the coil 11 received via the receiving interface 19. On the basis of this examination, which is essentially a determination of the inductance H of the coil 11, a conclusion regarding the distance of separation of the coil 11 and the position element 9 can be reached. On the basis of this conclusion, the incident pressure can be determined.
The first line L1 shows the progression of the inductance H when the coil 11 is positioned around 450 micrometers from the position element 9 in the direction perpendicular to the plane of the coil 11. The second line L2 i.e. progression shows the inductance H of the coil 11 when the position element 9 is separated from the coil 11 by 300 micrometers in the direction perpendicular to the plane of the coil 11. The third progression i.e. line L3 shows the inductance H of the coil 11 when the position element 9 is separated from the coil 11 by 150 micrometers in the direction perpendicular to the plane of the coil 11. Measurements of the coil 11 inductance H can be performed at this scale with an accuracy of +/−5%.
If a ferrite material is used for the position element 9, a different effect will occur. Because the ferrite material is electrically nonconductive, i.e. an insulator, no eddy current is produced in the ferrite. Rather, due to the relative permeability, which can be greater than one hundred, the position element 9 behaves as the magnetic field concentrator, or magnetic conductor for the field produced by the planar coil 11. This in turn increases the inductance H value of the planar coil 11 with respect to its nominal value.
In a flow measurement application such as the one depicted in
The systems of device 1 for measuring pressure and container as depicted in
Number | Date | Country | Kind |
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10 2017 205 054.3 | Mar 2017 | DE | national |
This application is a filing under 35 U.S.C. § 371 of International Patent Application PCT/EP2018/053970, filed Feb. 19, 2018, claiming priority to German Patent Application 10 2017 205 054.3, filed Mar. 24, 2017. All applications listed in this paragraph are hereby incorporated by reference in their entireties.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2018/053970 | 2/19/2018 | WO | 00 |