Optimization of pneumatic activity sensor : Development of a low friction seal

Abstract: In this thesis, the development of a new type of seal is presented along with the steps taken to attain the conclusive design. The results are presented in this paper as a cross-sectioned CAD-model along with the selection of materials and suggestions for future work. The project was commissioned by the multi-discipline engineering consultancy company Projektengagemang AB in Karlstad, Sweden, and carried out as a master’s thesis at Karlstad University. The commission was due to a demand for a new type of sealing solution, as friction is a problem within the field of micro-pneumatics. The work done consists of a study of different low-friction materials where a 30/70 PTFE/PEEK compound was selected as it displayed promising friction and wear properties. The material was then implemented into a design concluded by employing a product development process. The result rendered a prototype for a new kind of low-friction seal which uses the fluid pressure to achieve a sealing contact load between a piston/rod and the seal, which also was the goal set to achieve at the start of the project. Additionally, a design of experiments study was conducted to settle what design parameters were significant with respect to the contact load. For proceeding, making the concept a product ready for production, additional work is needed in the form of experimental material testing, development of a leakage model to optimize the contact load, determination of temperature and creep behaviour, as well as sufficient field testing. Lastly, a die tool must be designed for manufacturing with injection moulding as well as determining if any further processing is required.