The current research presents recent respective to the work development of a ceramic clevis sensor for online substance concentration measurements. The aim was to develop a robust and acid-resistant sensor device, which can be easily included in existing procedural pipeline systems. To archive those goals a lot of factors had to be checked. For the substance concentration measurements a capacitive sensor effect was chosen. With this method even low substance concentrations down to one-tenth of a per cent can be indentified.

For the package material zirconium oxide (tetragonal zirconia polycrystal – TZP) was used. Zirconium oxide is a technical ceramic which is wear-resistant, acid-resistant, has a low thermal conductivity, is electrically isolating and can be uses in a ceramic injection molding (CIM) process. In the phase of the sensor design process multiple geometries for the sensor effect and integration space for the evaluation electronics had to be considered. A standardized DN 40 DIN 32676 flanged joint was also added for an unproblematic connection to the pipelines. All these needed geometries had to be integrated into one ceramic element. As a result of these requirements a 3D CAD model of the sensor element was designed. The CAD-file has shown that there was only the CIM technology left to comprehend developed sensor geometry. CIM is a low cost process for large-scale production which is distinguished by high size accuracy. In the CIM process the material shrinkage, this is caused by the needed debindering and sintering steps, had to be considered.

The developed ceramic clevis sensor was successfully tested in multiple fluidic systems. It has left the test phase and is now ready for maturity phase.

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