Hall Sensor Magnetic Oil Plug for Real-Time Debris Monitoring

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Solution Overview

Problem

Conventional magnetic oil plugs can only be examined during routine maintenance, lacking real-time monitoring capabilities for ferrous debris accumulation, which can lead to unscheduled failures and costly downtime.

Innovation Solution

Integration of a Hall-effect based ferrous debris monitoring sensor into a magnetic oil plug, enabling real-time detection of ferrous debris deposition through magnetic flux density measurements, and transmitting data for condition-based monitoring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional magnetic oil plugs are used, then ferrous debris can be accumulated, but real-time monitoring capability is lost and only routine maintenance examination is possible

Engineering Contradiction:

Improvereal-time monitoring capabilityVSAvoidmaintenance examination timing

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the purely mechanical accumulation method with an electronic sensing system. A Hall-effect sensor detects magnetic flux changes caused by ferrous debris accumulation in real-time, eliminating the need for manual examination during routine maintenance and enabling continuous monitoring.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent implements feedback by continuously measuring magnetic flux density through the Hall-effect sensor and providing real-time data about debris accumulation levels. This feedback loop allows the system to monitor debris buildup dynamically and trigger alerts or maintenance warnings when thresholds are exceeded.

Inventive Principle:

Principle #23Feedback

2Measurement precision

If Hall-effect sensor is integrated into magnetic oil plug, then real-time debris detection is enabled, but device complexity increases

Engineering Contradiction:

Improvedebris detection capabilityVSAvoidsensor assembly structure

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The patent merges the Hall-effect sensor, permanent magnets, and debris accumulation chamber into a single integrated magnetic oil plug assembly. This consolidation reduces the number of separate components and simplifies installation while maintaining real-time detection capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent creates a multi-functional device where the magnetic oil plug simultaneously performs debris accumulation, magnetic flux generation, and real-time detection functions. The same structure serves multiple purposes: collecting ferrous debris, creating the magnetic field, and sensing flux changes, thereby reducing overall system complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If permanent magnets with cavity are used, then Hall-effect sensor protection is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvesensor protectionVSAvoidcavity integration accuracy

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent places the Hall-effect sensor inside a cavity formed within the permanent magnet structure itself. This nesting approach protects the sensor while utilizing the magnet's own geometry to define the sensing chamber, reducing the need for separate precision manufacturing steps.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 real-time monitoring of debris levels, allowing for timely maintenance planning, prevention of costly failures, and reduction of downtime, thereby improving the overall health and efficiency of systems.

Implementation Method 1

a Hall-effect sensor configured within the cavity

Methodology Applied

Scientific EffectHall effect: Hall Effect

Implementation Method 2

one or more permanent magnets comprising a cavity on a first end

Methodology Applied

Scientific EffectMagnetic flux concentration: Magnetic Field

Data Source

PatentUS20250180675A1Novel concept with stacked magnets, flux concentrators & hall sensor in single package to measure ferrous debris collected anywhere around magnetic oil debris sensor periphery

Publication Date: 2025.06.05 HONEYWELL INTERNATIONAL INC

AI summary

A debris sensor apparatus comprising a head portion, a male-threaded portion, and a shaft comprising a debris sensor assembly, the debris sensor assembly comprising one or more permanent magnets comprising a cavity on a first end, a Hall-effect sensor configured within the cavity, a first pole piece configured adjacent to a second end of the one or more permanent magnets, and a second pole piece configured adjacent to the first end.