Cartridge Hydraulic Flow Sensor With PLC Feedback Control

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Solution Overview

Problem

Existing hydraulic flow sensors are difficult to integrate into hydraulic systems, requiring labor-intensive installation and maintenance, and lack easy engagement and disengagement from hydraulic circuit manifolds while providing fluid flow monitoring and automatic system adjustments.

Innovation Solution

A cartridge-style hydraulic flow sensor that can be conveniently inserted and removed from a hydraulic circuit manifold, featuring a programmable logic controller and Hall Effect Sensor to monitor fluid flow, allowing for automatic adjustment of the hydraulic system's operational parameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional hydraulic flow sensor is plumbed into a hydraulic line, then fluid flow monitoring capability is achieved, but installation becomes labor-intensive and requires cutting hydraulic lines

Engineering Contradiction:

Improvefluid flow monitoring capabilityVSAvoidinstallation ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The flow sensor is designed as a cartridge-style modular unit that can be independently installed and removed from the hydraulic manifold without cutting hydraulic lines. This segmentation allows the sensor to be plugged into a dedicated cartridge receptacle, simplifying installation and maintenance while maintaining monitoring capability

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A cartridge-style receptacle serves as an intermediary component between the hydraulic manifold and the flow sensor. This mediator allows the sensor to be easily inserted and removed without modifying the hydraulic lines themselves, resolving the contradiction between reliable monitoring and easy installation

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a conventional hydraulic flow sensor is plumbed into a hydraulic line, then fluid flow monitoring is achieved, but maintenance and replacement require cutting the hydraulic line

Engineering Contradiction:

Improvefluid flow monitoring capabilityVSAvoidsensor replacement ease

Core Design Contradiction:

ReliabilityVSEase of repair

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cartridge-style design enables the flow sensor to be easily removed and replaced as a complete unit without damaging the hydraulic system. The sensor can be discarded or sent for repair while the manifold and hydraulic lines remain intact and reusable

Inventive Principle:

Principle #34Discarding and recovering

3Measurement precision

If a hydraulic flow sensor is installed in a hydraulic system, then fluid flow rate can be monitored, but automatic adjustment of hydraulic system settings cannot be achieved

Engineering Contradiction:

Improvefluid flow rate monitoringVSAvoidautomatic system adjustment capability

Core Design Contradiction:

Measurement precisionVSExtent of automation

Solution Approach 1:

The flow sensor includes a Hall Effect sensor that detects impeller rotation and provides real-time flow rate data to a programmable logic controller (PLC). The PLC automatically adjusts hydraulic system settings based on this feedback, achieving both precise monitoring and automatic adjustment

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system uses the flow sensor data to automatically self-regulate hydraulic system operations through the PLC, which adjusts pump settings or valve positions without requiring manual intervention, thereby achieving automatic adjustment capability

Inventive Principle:

Principle #25Self-service

4Loss of information

If wires are added proximate to the hydraulic line for sensor communication, then communication between sensor and control unit is established, but device complexity increases

Engineering Contradiction:

Improvecommunication capabilityVSAvoidwiring complexity

Core Design Contradiction:

Loss of informationVSDevice complexity

Solution Approach 1:

The flow sensor cartridge is electrically connected to the hydraulic manifold through integrated contacts that engage when the cartridge is inserted. This merging of electrical and hydraulic connections eliminates the need for separate wire installations, reducing overall system complexity while maintaining communication capability

Inventive Principle:

Principle #5Merging (Combining)

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

Enables easy installation and maintenance of hydraulic flow sensors, providing real-time monitoring and automatic system adjustments to achieve desired fluid flow rates and system performance without cutting hydraulic lines.

Implementation Method 1

a Hall Effect Sensor to monitor fluid flow

Methodology Applied

Scientific EffectHall Effect: Hall Effect

Data Source

PatentUS12535344B2Programmable cartridge-style hydraulic flow sensor

Publication Date: 2026.01.27 DIETEL DALE G

AI summary

A flow sensor for sensing fluid flow. The flow sensor includes an exterior, interior, a circuit board, and first and second ports. The first and second ports permit fluid to flow into and out of the interior. A Hall Effect Sensor in the interior detects the number of revolutions of an impeller. An electric coupler interfaces with the flow sensor and a transmitter for communication of the revolutions of the impeller to a controller. The controller determines the rate of fluid flow in a conduit. The controller issues a command signal to a component of a hydraulic system to alter the rate of fluid flow in the conduit.