Fluid Flow Counter with Piston Sensor for Tool Usage Monitoring

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Solution Overview

Problem

Existing fluid-powered tools lack efficient and accurate methods for monitoring usage, often requiring manual and error-prone processes, which can lead to inconsistent results and premature tool failure.

Innovation Solution

A counter system that includes a fluid passage with a piston and sensor target, biased by a member, which moves within the passage when the tool is in operation, allowing a processing circuit to detect and count the sensor target's position to determine tool usage, either by time or cycles, using non-contact proximity sensing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If manual processes (e.g., punch cards) are used to monitor tool usage, then the monitoring can be performed without additional sensors or electronic components, but the process becomes tedious and error-prone

Engineering Contradiction:

Improvemonitoring system complexityVSAvoidusage monitoring accuracy

Core Design Contradiction:

Device complexityVSMeasurement precision

Solution Approach 1:

The patent replaces manual mechanical monitoring processes (punch cards) with an automated electronic sensing system. A sensor detects the position of a sensor target on the piston, and a processing circuit automatically counts cycles and calculates usage, eliminating manual intervention and improving accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The monitoring system is self-actuating through the fluid pressure itself. The fluid pressure moves the piston, which carries the sensor target past the sensor, automatically recording each cycle without external intervention or manual operation.

Inventive Principle:

Principle #25Self-service

2Measurement precision

If a sensor target and sensor system are implemented to automatically detect piston position, then usage monitoring accuracy improves, but the device complexity increases

Engineering Contradiction:

Improveusage monitoring accuracyVSAvoidmonitoring system complexity

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent merges the sensor target with the existing piston component, eliminating the need for separate mounting structures. The processing circuit is integrated into the tool's existing control system, reducing overall device complexity while maintaining measurement precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The sensor target acts as an intermediary element that translates mechanical piston movement into detectable signals for the sensor. This simple magnetic or reflective target provides a reliable interface between the mechanical system and electronic detection without adding complex transducers.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If the biasing member force is increased to ensure the sensor target stays away from the sensor during idle periods, then measurement reliability improves, but the force required to move the piston during operation must be even greater

Engineering Contradiction:

Improvemeasurement reliabilityVSAvoidfluid force required to move piston

Core Design Contradiction:

ReliabilityVSForce

Solution Approach 1:

The patent optimizes the biasing force parameter to achieve reliable idle positioning without excessive operational force requirements. The biasing member (spring or elastic element) is designed with specific stiffness and preload characteristics that ensure the sensor target remains clear of the sensor during idle periods while allowing smooth piston movement during operation.

Inventive Principle:

Principle #35Parameter changes

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

Provides accurate and automated monitoring of tool usage, enabling timely maintenance and reducing errors, thus extending the tool's operational life and improving maintenance efficiency.

Implementation Method 1

A biasing member applies a first force to the piston to bias the sensor target away from the predetermined range

Methodology Applied

Scientific EffectElastic force: Elasticity

Implementation Method 2

A sensor is configured to detect when the sensor target is within a predetermined range along the passage

Methodology Applied

Scientific EffectProximity sensing:

Implementation Method 3

The first force is less than a force applied by the fluid moving along the fluid line when the tool is in operation with the sensor target being positioned in the predetermined range

Methodology Applied

Scientific EffectFluid pressure: Pressure Increase

Data Source

PatentUS10140480B2Electronic counter for fluid flow tools

Publication Date: 2018.11.27 APEX BRANDS INC

AI summary

A counter to monitor an amount of tool use that includes a fluid passage (23) with an inlet (21) and an outlet (22). A piston (30) and sensor target (50) (e.g., magnet) are positioned along the passage and are biased towards a first position by a biasing member (40). When the tool is not in operation, the piston and sensor target are located at a first position due to the biasing force. When the tool is in operation, fluid moves along the fluid passage. A force applied by the moving fluid on the piston and sensor target overcomes the force applied by the biasing member and moves the piston and sensor target along the fluid passage to a second position. A sensor is configured to sense the sensor target at the second position. A processing circuit (62) determines the tool usage based on the detection of the sensor target at the second position by the sensor.