Immersion Pump Float Control via Hall Sensor
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Solution Overview
Problem
Existing synchronous immersion pumps face difficulties in precise turn-off control, especially when almost empty, leading to potential damage from continuous on-off cycles and requiring external float control devices that are not always effective.
Innovation Solution
Incorporating a float control device within the pump body with a Hall-effect magnetic sensor and a movable float equipped with a permanent magnet, allowing for adjustable operating modes and improved turn-off control by ensuring the magnet's position relative to the sensor prevents vacuum operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a float control device is used to control pump operation, then the pump can be turned on and off based on fluid level, but continuous on-off cycles can damage the pump control device and pump when little water remains
Solution Approach 1:
The patent replaces the traditional mechanical float control device with a magnetic sensor-based control system. The Hall effect sensor detects the position of a magnetic float, eliminating mechanical contact and wear. This substitution resolves the contradiction by maintaining automatic control functionality while significantly improving reliability and durability against continuous operation cycles.
Solution Approach 2:
The patent introduces a magnetic field as an intermediary between the float and the sensor. Instead of direct mechanical contact, the magnetic float interacts with the Hall effect sensor through magnetic field detection. This intermediary approach allows for non-contact sensing, reducing mechanical wear and improving the durability of the control device during repeated on-off cycles.
2Object-affected harmful factors
If the pump is turned off when little water remains, then water intake damage is prevented, but precise turn-off control is difficult to achieve
Solution Approach 1:
The patent uses a Hall effect sensor to replace mechanical level sensing, providing more precise and reliable detection of the float position. This magnetic sensing approach enables accurate detection of the fluid level threshold, allowing the pump to turn off precisely when appropriate without mechanical wear or response delays.
Solution Approach 2:
The patent implements a feedback control system where the Hall effect sensor continuously monitors the float position and provides feedback to the control circuit. This feedback mechanism enables precise control by adjusting the pump operation based on real-time level detection, ensuring the pump turns off at the optimal moment to prevent air intake damage.
3Volume of moving object
If a float control device is incorporated in the pump body, then the pump becomes more compact and integrated, but the construction complexity increases
Solution Approach 1:
The patent merges the float control device components directly into the pump body structure. The Hall effect sensor, magnetic float, and control circuit are integrated within the pump housing, eliminating the need for separate external control devices. This merging approach achieves compactness and integration while managing complexity through unified design.
Solution Approach 2:
The patent designs the integrated control system to serve multiple functions: level detection, pump control, and protection against air intake. By making the control device multi-functional, the patent reduces the need for separate components, thereby achieving compactness without proportionally increasing complexity.
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 enhances the pump's control accuracy, reduces damage from air intake, and integrates the float control system within the pump, making it more compact and cost-effective while ensuring reliable operation in both automatic and manual modes.
Implementation Method 1
a sensor element of said control device is housed in the pump body in correspondence with said float
Data Source
AI summary
The present invention relates to a synchronous pump structure, particularly to an immersion pump (1) equipped with a float control device (3) and comprising a synchronous electric motor (2) with a permanent magnet rotor (8). The pump (1) is so structured that the float (16) of the control device (3) is incorporated in an envelope (11), externally associated with the body (15) of the pump (1). A sensor element (4) of the control device (3) housed in the pump body (15) in correspondence with the float (16) is also provided.