Cartridge Hydraulic Flow Sensor Manifold Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing hydraulic flow sensors are difficult to integrate into hydraulic systems, requiring labor-intensive installation and maintenance, and lack the ability to be easily engaged or disengaged from hydraulic circuit manifolds while providing communication with controllers for automatic fluid flow adjustments.
Innovation Solution
A cartridge-style hydraulic flow sensor that can be conveniently inserted and removed from hydraulic circuit manifolds, equipped with an impeller and Hall Effect Sensor, allowing for bidirectional fluid flow sensing and automatic adjustment of fluid flow rates through communication with a programmable logic controller or remote processor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a hydraulic flow sensor is plumbed into an existing hydraulic line, then the sensor can monitor fluid flow, but the installation requires cutting the hydraulic line and performing labor-intensive plumbing work
Solution Approach 1:
The flow sensor is designed as a separate cartridge module that can be independently installed into a manifold without modifying existing hydraulic lines. This segmentation allows the sensor to be plumbed into the system through a dedicated port rather than requiring cutting into existing lines, thereby maintaining monitoring capability while dramatically simplifying installation.
2Reliability
If a conventional hydraulic flow sensor is installed in a hydraulic line, then fluid flow can be sensed, but maintenance and replacement require cutting the sensor out of the hydraulic line
Solution Approach 1:
The sensor is designed as a removable cartridge module that can be easily extracted from the manifold for maintenance or replacement. This modular segmentation allows technicians to remove and replace the sensor without cutting hydraulic lines or performing complex disassembly, significantly improving ease of repair while maintaining continuous fluid flow sensing capability.
3Measurement precision
If a hydraulic flow sensor is integrated into a hydraulic system, then fluid flow rate can be monitored, but the system requires manual adjustment of control units to change flow rates
Solution Approach 1:
The flow sensor provides real-time feedback about fluid flow rates to the control system. This feedback enables automatic adjustment of hydraulic components based on actual flow conditions, eliminating the need for manual intervention. The precise measurement capability of the sensor directly supports this automated feedback control, improving both measurement precision and ease of operation.
4Reliability
If a hydraulic flow sensor is plumbed into existing hydraulic lines, then flow monitoring is achieved, but the installation process is labor-intensive and requires skill to maintain line integrity
Solution Approach 1:
The sensor is designed as a self-contained cartridge module that interfaces with the hydraulic system through a dedicated manifold port. This segmentation eliminates the need to cut into existing hydraulic lines during installation, allowing for quick plug-and-play integration. The modular design maintains reliable fluid flow monitoring while dramatically improving installation productivity by eliminating complex plumbing work.
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, automatic adjustment of fluid flow rates, and real-time monitoring of hydraulic system performance without the need to cut or breach hydraulic lines, improving operational efficiency and reducing labor costs.
Implementation Method 1
A Hall Effect Sensor may be in communication with a programmable logic controller for a hydraulic system or machine
Data Source
AI summary
A cartridge-style flow sensor for sensing fluid flow. The includes an exterior, interior, head, base, 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 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 automatically issues a command signal to a component of a hydraulic system to alter the rate of fluid flow in the conduit. The cartridge hydraulic flow sensor is easily and releasably engaged to a cavity of a hydraulic circuit manifold.