Impeller Magnet Groove Integration for Accurate Low-Flow Sensing
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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 magnetic field detection and improved assembly efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the impeller and magnet groove are connected by a spindle, then the structure can be assembled, but assembly gaps, looseness and misalignment occur, affecting rotational synchronization
Solution Approach 1:
The magnet groove is integrally formed with the impeller as a single piece, eliminating the need for separate magnet components and spindle connections. This integration removes assembly gaps and misalignment issues, ensuring perfect rotational synchronization between the impeller and magnet while simplifying the manufacturing process.
2Ease of manufacture
If separate impeller and magnet groove parts are used, then manufacturing flexibility is improved, but assembly gaps and misalignment reduce sensitivity and accuracy
Solution Approach 1:
By integrating the magnet groove into the impeller structure, the patent eliminates assembly gaps that cause measurement errors. The unified structure ensures precise rotational synchronization, directly improving flow detection accuracy and sensitivity while maintaining manufacturing feasibility through integral forming processes.
3Reliability
If the magnet is firmly fixed in the magnet groove, then rotational synchronization is maintained, but assembly complexity and maintenance difficulty increase
Solution Approach 1:
The magnet is designed as a separate, detachable component from the impeller, allowing for easy installation and removal. This segmentation maintains rotational synchronization when assembled while significantly improving maintenance capability, as the magnet can be replaced without removing the entire impeller assembly.
4Device complexity
If assembly gaps and looseness are present, then manufacturing is simplified, but rotational misalignment reduces sensitivity under low flow conditions
Solution Approach 1:
The integral formation of the magnet groove with the impeller eliminates assembly gaps that would cause rotational misalignment. This unified structure ensures precise magnetic field generation and detection, directly improving sensitivity under low flow conditions while maintaining relatively simple manufacturing through integral forming processes.
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 maintaining rotational synchronization, reducing mechanical wear, and facilitating easy maintenance, while ensuring reliable and precise flow measurement 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
Implementation Method 2
The magnet groove is generally disposed on or near the impeller and includes one or more magnets used to generate a magnetic field that changes with the rotation of the impeller
Data Source
AI summary
A flow sensor has a housing through which water flow passes. A fixing seat and a holder are provided in the housing. A central rotating shaft is connected between the fixing seat and the holder. An impeller is mounted on the central rotating shaft. The impeller includes a plurality of blades. At least one of the blades has a magnet mounting groove that is integrally formed with an outer side of the blade. A magnet is detachably connected in the magnet mounting groove. A Hall sensor 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.