Electric Ball Valve Shaft Buffering for Accurate Hall Position Sensing
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Solution Overview
Problem
Existing electric ball valves face challenges in ensuring control accuracy, optimizing space utilization, reducing production and maintenance costs, and minimizing electromagnetic interference.
Innovation Solution
The electric ball valve incorporates a magnetic ring and Hall sensor with a buffer part at the shaft part to improve detection accuracy and stability, and a manufacturing method involving separate assembly of components to optimize production and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a Hall sensor and magnetic ring are added to improve control accuracy, then measurement precision improves, but device complexity increases
Solution Approach 1:
The patent integrates the Hall sensor and magnetic ring into the existing valve structure, combining the detection function with the mechanical components. The magnetic ring is mounted on the shaft part, and the Hall sensor is positioned to detect its position, merging the detection system with the drive mechanism rather than adding separate independent components.
Solution Approach 2:
The shaft part serves multiple functions: it transmits rotational motion from the motor to the valve core, and simultaneously serves as the mounting structure for the magnetic ring. The magnetic ring both marks position for detection and is mechanically coupled to the shaft, making the structure multi-functional and reducing overall complexity.
2Measurement precision
If multiple components are integrated to improve control accuracy, then measurement precision improves, but manufacturing complexity increases
Solution Approach 1:
The patent divides the valve into distinct modular components: the shaft part with the magnetic ring mounted separately, the Hall sensor positioned independently, and the valve core assembly. This segmentation allows each component to be manufactured and tested independently, then assembled together, reducing overall manufacturing complexity while maintaining detection accuracy.
Solution Approach 2:
The magnetic ring is pre-mounted on the shaft part before final assembly, and the Hall sensor is pre-positioned in the housing. These preliminary actions ensure proper alignment and spacing are achieved during assembly, reducing the need for complex post-assembly adjustments and simplifying the manufacturing process.
3Measurement precision
If detection components are added to improve control accuracy, then measurement precision improves, but electromagnetic interference increases
Solution Approach 1:
The patent separates the detection function (Hall sensor and magnetic ring) from the power generation components (motor). The Hall sensor is positioned in a location that minimizes exposure to electromagnetic fields generated by the motor, effectively extracting the sensitive detection elements from the high-interference zone while maintaining their functional relationship with the shaft.
4Volume of moving object
If the structure is made more compact to optimize space utilization, then volume decreases, but manufacturing complexity increases
Solution Approach 1:
The patent employs a nested arrangement where the magnetic ring is mounted on the shaft part, the Hall sensor is positioned within the housing cavity, and the valve core is nested within the valve body. This nesting approach maximizes space utilization by placing components within the internal volumes of other components rather than requiring additional external space.
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
Enhances control precision and stability while reducing production and maintenance costs, and minimizes electromagnetic interference.
Implementation Method 1
The electric ball valve includes a magnetic ring and a Hall sensor
Data Source
AI summary
An electric ball valve, comprising: a shaft portion, a magnetic ring, and a Hall sensor, the Hall sensor being in electrical and signal connection with a circuit board, the shaft portion being connected to an output shaft and capable of rotating along with the output shaft, the magnetic ring being sleeved on the radial periphery of the shaft portion, and the magnetic ring being capable of rotating along with the shaft portion; and a cushioning portion, the cushioning portion directly or indirectly abutting against an end of the shaft portion. Also provided is a method for manufacturing an electric valve. The present electric ball valve is provided with the cushioning portion at the end of the shaft portion, thereby facilitating reducing downward plays of the magnetic ring and the shaft portion in the axial direction during rotation along with the output shaft.