Impeller Magnet Groove Integration for Low-Flow Sensor Accuracy
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Solution Overview
Problem
Conventional flow sensors with impeller and magnet grooves suffer from assembly gaps, looseness, and misalignment, leading to reduced sensitivity and accuracy, especially under low flow conditions, and incorrect flow data recording.
Innovation Solution
A flow sensor design with integrally formed magnet mounting grooves on the impeller blades and a detachable magnet connection, synchronized with a Hall sensor, ensuring precise rotational alignment and improved assembly, and a modular housing structure for ease of maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the impeller and magnet groove are connected by a spindle to form separate parts, then the manufacturing and assembly process is simplified, but assembly gaps, looseness and misalignment occur resulting in reduced rotational synchronization
Solution Approach 1:
The magnet groove is integrally formed with the impeller blade as a single piece, eliminating the need for a separate magnet groove component and spindle connection. This merging of parts ensures perfect rotational synchronization between the impeller and magnets while maintaining ease of manufacture through integral forming processes
2Adaptability or versatility
If the impeller and magnet groove are connected by a spindle, then the structure is more flexible, but assembly gaps and looseness occur affecting sensitivity under low flow conditions
Solution Approach 1:
By integrating the magnet groove directly into the impeller blade structure, the patent eliminates assembly gaps and looseness that compromise sensitivity. The integral design ensures precise magnetic field modulation even under low flow conditions, maintaining measurement precision while preserving structural flexibility through the blade's inherent design
3Ease of operation
If separate parts are used for impeller and magnet groove, then assembly is more flexible, but misalignment occurs leading to incorrect flow data recording
Solution Approach 1:
The magnet groove is formed as an integral part of the impeller blade, eliminating misalignment issues between separate components. This unified structure ensures that the magnets remain precisely positioned relative to the impeller rotation, guaranteeing accurate flow data recording while maintaining assembly flexibility through integral forming techniques
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
Enhances sensitivity and accuracy by ensuring synchronous rotation, reduces mechanical wear, and facilitates easy maintenance, providing stable and precise flow measurements across varying conditions.
Implementation Method 1
A Hall sensor is mounted on an outer wall of the housing and corresponds in position to the magnet
Data Source
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AI summary
A flow sensor has a housing (1) through which water flow passes. A fixing seat (2) and a holder (3) are provided in the housing (1). A central rotating shaft (4) is connected between the fixing seat and the holder. An impeller (5) is mounted on the central rotating shaft (4). The impeller includes a plurality of blades (51). At least one of the blades has a magnet mounting groove (52) that is integrally formed with an outer side of the blade. A magnet (6) is detachably connected in the magnet mounting groove. A Hall sensor (7) is mounted on an outer wall of the housing and corresponds in position to the magnet. The flow sensor has the advantages of higher sensitivity and accuracy.