Eccentric Screw Pump Stator With Vulcanized Sensor Integration

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Solution Overview

Problem

Existing eccentric screw pumps lack efficient and cost-effective sensor integration, leading to delayed error detection, increased manufacturing effort, and vulnerability to product piracy, with current sensors being retrofitted post-production, causing unnecessary wear and tear.

Innovation Solution

Integrate sensors into the elastomer stator during manufacturing by vulcanization, ensuring they are inseparably connected, allowing for real-time data collection and reducing manufacturing steps.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If sensors are retrofitted to the stator after production, then sensor installation is possible, but manufacturing effort increases and costs rise

Engineering Contradiction:

Improveerror detection capabilityVSAvoidmanufacturing effort

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Sensors are integrated into the stator during the vulcanization process itself, rather than being installed afterward. The sensor holders and cable guides are molded directly into the stator as it is being manufactured, eliminating the need for post-production drilling and installation steps.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sensor integration process is merged with the stator manufacturing process. The vulcanization of the elastomer material simultaneously creates the stator structure and embeds the sensors, combining two separate operations (stator production and sensor installation) into one unified process.

Inventive Principle:

Principle #5Merging (Combining)

2Measurement precision

If expensive industrial sensors are used for data recording, then measurement accuracy improves, but product cost increases

Engineering Contradiction:

Improveoperating data recording accuracyVSAvoidproduct cost

Core Design Contradiction:

Measurement precisionVSQuantity of substance

Solution Approach 1:

The patent employs cost-effective sensor solutions that are integrated directly into the stator manufacturing process, replacing expensive retrofitted industrial sensors. The sensors are embedded during vulcanization, eliminating the need for additional metal sleeves and complex installation hardware.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If metal sleeves are used to anchor sensors in the stator, then sensor fixation is achieved, but radial expansion movements are obstructed

Engineering Contradiction:

Improvesensor fixationVSAvoidradial expansion movement

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The metal sleeve component is completely removed from the design. Instead of using a separate metal anchoring element, the sensor holders are molded directly from the elastomer material of the stator itself, allowing radial expansion without mechanical obstruction.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The material parameter of the sensor holder changes from metal to elastomer. This material substitution allows the holder to flex and expand radially with the stator while still providing adequate sensor fixation through the elastomeric material's inherent bonding properties.

Inventive Principle:

Principle #35Parameter changes

4Reliability

If retroactive machine processing is performed on the stator for sensor installation, then sensors can be installed, but manufacturing complexity increases

Engineering Contradiction:

Improvesensor installationVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Sensor holders, cable guides, and sealing structures are all molded into the stator during the initial vulcanization process. This preliminary integration eliminates the need for subsequent drilling, tapping, and assembly operations that would increase manufacturing complexity.

Inventive Principle:

Principle #10Preliminary action

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 cost-effective sensor integration, enhances detection of operational issues, reduces manufacturing effort, and prevents counterfeiting by ensuring sensors are inseparably connected, providing continuous data monitoring and improved stator recognition.

Implementation Method 1

The stator has at least one sensor, which is inseparably connected to the stator - i.e., is completely vulcanized therein or is vulcanized therein at least partly

Methodology Applied

Scientific EffectVulcanization:

Data Source

PatentUS20260098535A1Eccentric screw pump

Publication Date: 2026.04.09 NETZSCH PUMPEN & SYST

AI summary

An eccentric screw pump with a helical rotor and a stator made of an elastomer material, in which the rotor rotates by forming several pump chambers, wherein the stator is vulcanized into a preferably metal support pipe, wherein the stator has at least one sensor, which is inseparably connected to the stator, wherein the inseparable connection between the stator and senor is made by vulcanization.