High-sensitivity, high-precision integrated flow sensor

Abstract

A high-sensitivity, high-precision integrated flow sensor includes a housing for water flow, a mounting base and a support within the housing, a central rotating shaft connecting the mounting base and the support, an impeller mounted on the central rotating shaft, and multiple blades on the impeller. At least one blade has an integrated magnet mounting groove on its outer side, in which a magnet is detachably connected. A Hall effect sensor corresponding to the position of the magnet is mounted on the outer wall of the housing. This invention offers the advantages of higher sensitivity and accuracy.

Description

[Technical Field]

[0001] This invention relates to the field of flow sensor technology, and more particularly to a high-sensitivity, high-precision integrated flow sensor. [Previous Technology]

[0002] Many conventional flow sensors typically employ a mechanical structure consisting of an impeller and a magnetic slot to detect fluid flow. In this design, the impeller is placed within the fluid path and rotated by the flowing fluid. The magnetic slot, usually fixed to or near the impeller, contains one or more magnets used to generate a magnetic field that changes with the rotation of the impeller. By detecting these changes in the magnetic field, the flow sensor can convert them into flow data.

[0003] However, this structural design has some significant drawbacks. First, since the impeller and magnet slot are two separate parts, they need to be connected by a shaft. This design not only increases the complexity of manufacturing and assembly, but also frequently results in assembly gaps, loosening, and misalignment between the two parts in actual use. These problems can lead to a lack of complete synchronization between the rotation of the impeller and the magnet, thus affecting the overall performance of the flow sensor.

[0004] Specifically, due to the reduced synchronization of impeller and magnet rotation, capturing the pulse signals generated by fluid flow becomes more difficult, especially under low flow conditions. This directly affects the sensitivity of the flow sensor in detecting flow, making it difficult to accurately capture minute flow changes. Furthermore, mismatches and misalignments between components negatively impact the accuracy of flow data. These problems not only significantly reduce the performance of the flow sensor but may also lead to erroneous flow data recording, thereby affecting the normal operation of the entire system.

[0005] Therefore, it is necessary to further improve and perfect the existing technology to overcome these shortcomings, and the present invention is made based on this situation. [Summary of the Invention]

[0006] The purpose of this invention is to overcome the shortcomings of the prior art and provide a flow sensor with higher sensitivity and accuracy.

[0007] To solve the above-mentioned technical problems, the present invention provides a high-sensitivity and high-precision integrated flow sensor, including a housing that allows water to flow through, a fixed base and a bracket inside the housing, a central rotating shaft rotatably connected between the fixed base and the bracket, an impeller fixedly mounted on the central rotating shaft, a plurality of blades on the impeller, at least one blade having an integral magnet mounting groove on its outer side, a magnet being detachably connected to the magnet mounting groove, and a Hall sensor corresponding to the position of the magnet being mounted on the outer wall of the housing.

[0008] Preferably, the magnet is interference-fitted in the corresponding magnet mounting slot.

[0009] Preferably, the magnet mounting slots are provided in multiple ways, and each magnet mounting slot is evenly distributed along the impeller axis on the corresponding blade.

[0010] Preferably, both the fixing base and the bracket can be detachably installed in the housing, and the bracket and the fixing base can also be detachably connected.

[0011] Preferably, the housing includes an upper shell and a lower shell, the lower shell is provided with a limiting step, the fixing seat is inserted into the lower shell from top to bottom and abuts against the limiting step, the upper shell is detachably connected to the lower shell, and the lower end of the upper shell presses down against the fixing seat.

[0012] Preferably, the lower end of the upper shell is inserted into the opening at the upper end of the lower shell, and the two are tightly connected by a U-shaped pin and a sealing ring.

[0013] Preferably, the inner sidewall of the lower shell is provided with a limiting groove for inserting and positioning the bracket.

[0014] Preferably, the fixed base is provided with a water distribution baffle, and the water distribution baffle is provided with water distribution holes that are evenly distributed and face the corresponding blade positions.

[0015] Compared with the prior art, the present invention has the following advantages:

[0016] 1. In this invention, since the magnet, blade, and magnet mounting slot are integrated into a single design, the rotation of the magnet is strictly synchronized with the rotation of the impeller, which greatly improves the sensitivity and accuracy of the flow sensor in detecting flow rate. Furthermore, the integrated design eliminates errors caused by component gaps and looseness in traditional designs, ensuring the reliability of the flow sensor and the accuracy of the measurement data.

[0017] 2. The detachable design of the magnet facilitates disassembly, maintenance and replacement, and also helps to reduce production and assembly costs.

[0018] 3. The magnet mounting slot is located on the outer side of the blade, so the movement radius of the magnet in the magnet mounting slot is relatively large, which is beneficial to improving the sensitivity of the sensor. In addition, the design of the magnet moving on the outer side also helps to reduce the structural complexity and torsional strength requirements of the impeller center.

[0019] 4. Both the mounting base and the bracket are detachably installed inside the housing, allowing for convenient assembly into the housing. Furthermore, the bracket and the mounting base can be easily connected or disassembled. This design increases the modularity and ease of maintenance of the device, while also simplifying the assembly and disassembly process.

[0020] 5. The fixed base is equipped with a water-distributing baffle, which has multiple water-distributing holes. This design facilitates uniform fluid distribution, reduces uneven load on the impeller, thereby reducing vibration and noise, and improving the efficiency and lifespan of the entire device. The fluid can act more directly and effectively on the impeller, which reduces the loss of fluid kinetic energy, thus improving rotational efficiency and overall dynamic performance. For some applications requiring high-precision flow control, the uniform distribution of water-distributing holes and the precise alignment with the blades ensure stable and controllable flow, which is particularly important in precision equipment such as flow sensors.

Implementation Method

[0022] As shown in Figures 1 to 4, a high-sensitivity and high-precision integrated flow sensor includes a housing 1 through which water can flow. The housing 1 contains a fixed base 2 and a bracket 3. A central rotating shaft 4 is rotatably connected between the fixed base 2 and the bracket 3. That is, the fixed base 2 and the bracket 3 form a frame for mounting the central rotating shaft 4. The upper and lower ends of the central rotating shaft 4 are rotatably inserted into the fixed base 2 and the bracket 3 respectively, and can rotate freely between them.

[0023] An impeller 5 is fixedly installed on the central rotating shaft 4. The impeller 5 is designed with multiple streamlined blades 51. Under the push of the water flow, they will rotate around the central rotating shaft 4 and reflect the flow rate through precise rotation speed.

[0024] It is worth noting that at least one blade 51 on the impeller 5 has a magnet mounting groove 52 integrated on its outer side (preferably, two symmetrical blades 51 on the impeller 5 each have a magnet mounting groove 52 integrated on their outer sides), which are integrally formed with the impeller 5 and blades 51 through an integrated injection molding process. This integrated design not only ensures the synchronous rotation of the magnet 6 and the blades 51, thereby improving the accuracy of flow measurement, but also simplifies the assembly process and enhances the overall structural strength.

[0025] In this design, the magnet 6 is typically made of magnetic material and is designed to be detachably connected and placed in the magnet mounting slot 52. The detachable design of the magnet 6 facilitates disassembly, maintenance, and replacement, and also helps to reduce production and assembly costs.

[0026] Correspondingly, a Hall sensor 7 is installed on the outer wall of the housing 1 to detect changes in the magnetic field of the magnet 6. The Hall sensor 7 is positioned corresponding to the magnet 6, and can accurately capture changes in the magnetic field generated by the magnet 6.

[0027] In this invention, since the magnet 6, blade 51, and magnet mounting groove 52 are integrated into a single design, the rotation of the magnet 6 is strictly synchronized with the rotation of the impeller 5. This greatly improves the sensitivity and accuracy of the flow sensor in detecting flow rate. In addition, the integrated design eliminates errors caused by component gaps and looseness in traditional designs, ensuring the reliability of the flow sensor and the accuracy of the measurement data.

[0028] More specifically, the magnet 6 is interference-fitted into the corresponding magnet mounting groove 52. This design achieves a firm connection between the magnet 6 and the magnet mounting groove 52, ensuring that the magnet will not shift during impeller rotation, thereby avoiding potential problems that could reduce measurement accuracy.

[0029] It is worth noting that the magnet mounting slot 52 is located on the outer side of the blade 51, so the radius of motion of the magnet 6 in the magnet mounting slot 52 is relatively large, which is beneficial to improving the sensitivity of the sensor. More specifically, since the magnet 6 is located on a larger radius of motion, the centrifugal force it generates when the impeller 5 rotates is also relatively large. In this way, the change in the magnetic field generated by the magnet 6 when it rotates by a fixed angle can be detected by the Hall sensor 7 at a greater distance, thereby improving the sensitivity and measurement accuracy of the sensor.

[0030] Physically, an increased radius of motion means a higher linear velocity for the magnet 6 at the same rotational speed. Since the Hall sensor 7 detects changes in the magnetic field, the rapid movement of the magnet 6 leads to an increase in the frequency and intensity of these changes, allowing the Hall sensor 7 to more sensitively detect flow rate changes. In practical applications, even very small flow rate fluctuations can be detected promptly and accurately converted into electrical signals, thus providing highly precise flow control and monitoring capabilities.

[0031] Furthermore, the design of the magnet 6 moving on the outside also helps to reduce the structural complexity and torsional strength requirements of the impeller center, because the magnet 6 is not placed on or near the central shaft 4, thereby reducing the stress burden on the central shaft during high-speed rotation. This design not only improves the response speed and accuracy of the sensor, but also helps to enhance the durability and reliability of the entire device.

[0032] To further improve the overall performance and measurement accuracy of the flow sensor, preferably, the magnet mounting slot 52 is not just a single slot, but rather a design with multiple (two or more) magnet mounting slots (two magnet mounting slots are shown in the figure), and these magnet mounting slots are evenly distributed along the axis of the impeller 5 on each corresponding blade 51. This evenly distributed design has several significant advantages:

[0033] 1. Balance: The even distribution of multiple magnets 6 can maintain the balance of the impeller 5, especially at high speeds, effectively reducing vibration and noise. A well-balanced impeller can reduce mechanical wear and extend the service life of the equipment.

[0034] 2. Sensitivity: Since the magnets are evenly distributed on different blades, it can be ensured that there are always magnets within the detection range of the sensor during the impeller rotation process. This can further improve the system's sensitivity to flow rate changes, especially when the flow rate changes are minute, it can still accurately capture them.

[0035] 3. Accuracy: Uniformly distributed magnets can more accurately reflect the impeller speed because the deviation of any one magnet will be balanced by the readings of the other magnets. This design helps improve the accuracy of the sensor throughout the entire operating range, especially in flow detection with a wide dynamic range.

[0036] 4. Uniform magnetic field distribution: The uniform distribution of multiple magnets helps to generate a uniform magnetic field in the moving area of ​​the impeller, which makes the readings of the Hall effect sensor more stable and consistent because it reduces the fluctuation of the magnetic field strength on the impeller rotation trajectory.

[0037] This design strategy of uniformly distributing multiple magnets significantly improves the performance of the equipment, ensuring that it can continuously and accurately measure flow under various working conditions, and adapt to a wider range of application needs.

[0038] More specifically, both the fixing base 2 and the bracket 3 are detachably installed inside the housing 1, allowing them to be easily assembled into the housing 1. Furthermore, the bracket 3 and the fixing base 2 can be easily connected or disassembled from each other. This design increases the modularity and ease of maintenance of the device, while also simplifying the assembly and disassembly process.

[0039] The housing 1 consists of two main parts: an upper housing 11 and a lower housing 12. In this design, a limiting step 121 is specially designed inside the lower housing 12 to support the fixing seat 2. During assembly, the fixing seat 2 can be inserted into the lower housing 12 from the top and positioned on the limiting step 121. This design ensures the stability of the fixing seat and simplifies the assembly process.

[0040] Then, the lower end of the upper shell 11 is inserted into the opening at the upper end of the lower shell 12, and the two are tightly connected by a U-shaped pin and a sealing ring to fix the entire structure. The bottom end of the upper shell 11 presses down on the fixing seat 2 to ensure the stability and vibration resistance of the fixing seat 2 during operation, and to avoid the decrease in instrument accuracy or damage to parts caused by vibration.

[0041] To further optimize the installation of the bracket 3, a limiting groove 122 is specially designed on the inner wall of the lower shell 12. The bracket 3 can be directly inserted into these limiting grooves to ensure accurate positioning and firm fixation of the bracket. This insertion and positioning method not only simplifies the assembly process of the device, but also provides a stable support structure to maintain the correct positional relationship of the internal mechanical components of the device.

[0042] This design allows the entire device to be quickly disassembled without special tools when maintenance, cleaning, or component replacement is required, greatly reducing maintenance and repair time costs. At the same time, the modular design facilitates potential upgrades and customized modifications, providing excellent flexibility and scalability to meet the specific needs of different users. These designs take into account both ease of operation and user maintenance costs, while also considering the long-term operational stability and economic benefits of the equipment.

[0043] More specifically, the fixed base 2 is provided with a water distribution baffle 21. This baffle is not only part of the structure, but also plays a crucial role in fluid dynamics. The water distribution baffle 21 is designed with a plurality of water distribution holes 211, which are not only evenly distributed on the baffle, but their positions are also aligned with the positions of the corresponding blades 51 below.

[0044] This design has many advantages:

[0045] 1. Uniform fluid distribution: By setting uniformly distributed water distribution holes 211 on the water distribution baffle 21, it can be ensured that the liquid is more evenly distributed before entering the impeller. This helps to reduce the uneven load on the impeller, thereby reducing vibration and noise, and improving the efficiency and life of the entire device.

[0046] 2. Enhanced dynamic performance: The water distribution hole 211 is set to the position of the corresponding blade 51, which means that the fluid can act on the impeller more directly and effectively. This direct action reduces the loss of fluid kinetic energy, thereby improving rotational efficiency and overall dynamic performance.

[0047] 3. Reduced energy consumption: By directing the fluid directly at the blades, additional energy loss due to changes in fluid direction can be reduced. This finely adjusted flow direction helps the entire system operate more energy-efficiently and reduces operating costs.

[0048] 4. Improved accuracy: For some applications that require high-precision flow control, the uniform distribution of the water distribution holes 211 and the design of the precisely aligned blades can ensure the stability and controllability of the flow, which is especially important in precision equipment such as flow sensors.

[0049] 5. Simplified structural design: The design of the water distribution baffle 21 integrates multiple functions, reducing the need for additional components to achieve the same function, thereby simplifying the overall structure and reducing manufacturing costs and maintenance difficulties. [Simplified Explanation of the Diagram]

[0021] Figure 1 is a three-dimensional structural schematic diagram of the present invention; Figure 2 is a cross-sectional view of the present invention; Figure 3 is an exploded schematic diagram of the fixing seat, support and impeller; Figure 4 is a three-dimensional structural schematic diagram of the lower shell.

Claims

1. A high-sensitivity, high-precision integrated flow sensor, characterized in that: it includes a housing for water flow, the housing comprising an upper shell and a lower shell, a fixing seat and a bracket provided inside the housing, the fixing seat and the bracket being detachably installed inside the housing, and the bracket and the fixing seat being detachably connected, the lower shell having a limiting step, the fixing seat being inserted into the lower shell from top to bottom and abutting against the limiting step, the upper shell being detachably connected to the lower shell, and the lower end of the upper shell pressing down against the fixing seat, a central rotating shaft being rotatably connected between the fixing seat and the bracket, an impeller being fixedly installed on the central rotating shaft, the impeller having multiple blades, at least one blade having an integral magnet mounting groove on its outer side, a magnet being detachably connected to the magnet mounting groove, and a Hall sensor corresponding to the position of the magnet being installed on the outer wall of the housing.

2. The high-sensitivity, high-precision integrated flow sensor as described in claim 1, wherein, The magnet is interference-fitted into the corresponding magnet mounting slot.

3. The high-sensitivity, high-precision integrated flow sensor as described in claim 1, wherein, The magnet mounting slots are provided in multiple ways, and each magnet mounting slot is evenly distributed along the impeller axis on the corresponding blade.

4. The high-sensitivity, high-precision integrated flow sensor as described in claim 1, wherein, The lower end of the upper shell is inserted into the opening at the upper end of the lower shell, and the two are tightly connected by a U-shaped pin and a sealing ring.

5. The high-sensitivity, high-precision integrated flow sensor as described in claim 1, wherein, The inner wall of the lower shell is provided with a limiting groove for the insertion and positioning of the bracket.

6. The high-sensitivity, high-precision integrated flow sensor as described in claim 1, wherein, The fixed base is provided with a water distribution baffle, and the water distribution baffle has a plurality of water distribution holes evenly distributed and facing the corresponding blade positions.

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