Flow Meter Impeller Shaft Segmentation for Low-Flow Rotation
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Solution Overview
Problem
Existing flow meters using Hall sensors face issues with increased friction due to a thicker impeller shaft, leading to potential breakage during installation and welding, and require higher water flow to start rotation, which affects detection reliability.
Innovation Solution
A flow meter design utilizing a thick installation positioning shaft for impeller positioning and a thin rotating positioning shaft as the pivotal shaft, reducing friction and requiring lower water flow for impeller rotation, with a clearance fit and guide hole configuration to prevent breakage during assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a thick pivotal shaft is used to support the impeller, then the impeller can be securely positioned during installation, but the friction force between the impeller and pivotal shaft increases, requiring higher water flow to start rotation
Solution Approach 1:
The shaft is divided into two distinct segments: a thick installation positioning shaft for secure positioning during assembly, and a thin rotating positioning shaft for low-friction rotation during operation. This segmentation allows each part to optimize its function independently.
Solution Approach 2:
The system transitions from a static thick shaft configuration to a dynamic configuration where the thin rotating positioning shaft enables smooth rotation. The clearance fit between the thin shaft and impeller hole allows the impeller to rotate freely with minimal friction during water flow operation.
2Force
If a thin pivotal shaft is used to reduce friction force, then lower water flow is required to start rotation, but the shaft becomes prone to breakage during installation and welding
Solution Approach 1:
The shaft system is segmented into two parts with different thicknesses: the installation positioning shaft is thick enough to withstand installation stresses, while the rotating positioning shaft is thin enough to minimize friction. This segmentation resolves the contradiction between strength and friction reduction.
Solution Approach 2:
The thick installation positioning shaft provides preliminary support and positioning during the assembly process, protecting the thin rotating positioning shaft from breakage during installation. Once installed, the thin shaft begins its primary function of reducing friction without having endured installation stresses.
3Manufacturing precision
If the impeller is securely fixed during installation, then positioning accuracy is improved, but the friction force increases and detection reliability decreases
Solution Approach 1:
The positioning shaft is segmented into two functional parts: the thick installation positioning shaft ensures accurate positioning during assembly, while the thin rotating positioning shaft minimizes friction during operation. This segmentation allows the system to achieve both positioning accuracy and detection reliability.
Solution Approach 2:
Different parts of the positioning shaft system have different local qualities: the installation positioning shaft has larger diameter for secure positioning and structural strength, while the rotating positioning shaft has smaller diameter for reduced friction. This local quality differentiation resolves the contradiction between positioning accuracy and detection reliability.
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
The design meets installation requirements while reducing friction and the required water flow, enhancing detection reliability by preventing shaft breakage and ensuring smooth operation.
Implementation Method 1
The flow meter using a Hall sensor comprises a magnet installed on an impeller
Implementation Method 2
A gap between the rotating positioning shaft and a hole wall of the rotating positioning hole is smaller than a gap between the installation positioning shaft and a hole wall of the installation positioning hole
Data Source
AI summary
A flow meter includes a lower shell flow meter includes: a lower shell; an upper shell disposed on the lower shell; a running water cavity disposed between the lower shell and the upper shell; and an impeller disposed in the running water cavity. The impeller includes: an installation positioning hole disposed at a bottom portion of the impeller; and a rotating positioning hole disposed at a top portion of the impeller. The flow meter includes an installation positioning shaft extending upward from the lower shell and configured to be inserted into the installation positioning hole; and a rotating positioning shaft extending downward from the upper shell and configured to be inserted into the rotating positioning hole.