Flow Sensor Switch Using Hall Effect and Intermediary Magnet
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Solution Overview
Problem
Conventional electrical switches used in fluid systems, such as reed switches and Hall effect sensors, are prone to failure due to mechanical shock, limited current capacity, and reliance on magnetic components which degrade over time, leading to unreliable operation.
Innovation Solution
A sensor/switch assembly that operates without magnetic components, utilizing a mechanical mechanism with a shuttle and spring assembly to detect fluid flow, changing contact positions in response to flow pressure, and generating an electrical output without the need for magnetic flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If reed switches are used for electrical switching functions, then sensitivity is improved, but reliability deteriorates due to mechanical shock and repetitive operation
Solution Approach 1:
The patent replaces the mechanical reed switch system with a magnetic field-based Hall effect sensor system. The Hall effect sensor detects changes in magnetic flux caused by magnet movement, eliminating mechanical contacts that are susceptible to wear and shock damage. This substitution maintains sensitivity through magnetic field detection while significantly improving reliability by removing mechanical failure points.
Solution Approach 2:
The patent introduces a magnet as an intermediary element that translates fluid flow into magnetic field changes. The magnet is coupled to the flow indicator and positioned near the Hall effect sensor, serving as a mediator that converts mechanical motion into detectable magnetic flux variations without requiring direct mechanical contact between the flow indicator and the sensor.
2Measurement precision
If reed switches operate at milliamp level current, then sensitivity is improved, but current capacity deteriorates
Solution Approach 1:
The Hall effect sensor system replaces the reed switch's mechanical contact mechanism with a magnetic field detection system. This allows the sensor to detect flow conditions and trigger switching functions without being limited by milliamp-level current constraints, enabling direct operation at higher current levels required for substantial load control.
3Ease of operation
If magnetic components are used in switches, then switching function is achieved, but reliability deteriorates over time due to magnetic flux degradation
Solution Approach 1:
The patent employs a Hall effect sensor that detects magnetic field changes without requiring the magnetic components to maintain fixed flux integrity over time. The magnet can move freely to indicate flow conditions, and the Hall effect sensor reliably detects these positional changes through magnetic field variations, eliminating the reliability issues associated with degrading magnetic flux in traditional reed switches.
4Ease of operation
If ferrous materials are attracted to magnets in switches, then magnetic switching is achieved, but reliability deteriorates due to material buildup and jamming
Solution Approach 1:
The patent positions the magnet and Hall effect sensor in close proximity, using the magnet as an intermediary that translates flow indicator position into detectable magnetic field changes. This close positioning allows reliable detection of flow conditions through magnetic field variations without requiring ferrous materials to be attracted to the magnet, thereby preventing material buildup and jamming issues.
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 solution provides a reliable and durable electrical switch that maintains contact states over extended usage without magnetic flux, reducing the risk of mechanical failure and maintaining performance across varying fluid flow conditions.
Implementation Method 1
A strong spring exerts a force between the shuttle and the collar
Implementation Method 2
a weak spring exerts a force between the mount assembly and the collar
Implementation Method 3
When fluid flows from the inlet through the orifice above a flow set point dynamic pressure, the contact member moves
Data Source
AI summary
A flow or level switch comprises a sensor/switch assembly which is adapted for mounting in connection with either a fitting having an offset defining a channel to detect fluid flow through an orifice into the channel or a tank having a ball float to detect the level of the ball float in the tank. A switch module comprises a control rod which reciprocates and activates a switch unit having a bi-positionable contact member. A follower, which may be in the form of an axle with an angularly fixed projection, engages the control rod to cause the contact member to move.