Magnetic Position Sensor for Wear-Free Coating Flow Measurement
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Solution Overview
Problem
Existing devices for dosing and mixing coating materials face issues with wear and tear, especially when using abrasive materials, and cannot function in explosive environments, such as those with solvent-containing lacquers.
Innovation Solution
A sensor system that detects the position of a movable magnetic object using a resistance track and a contact electrode with a magnetic position transmitter, allowing for contactless flow rate measurement, which is wear-free and suitable for explosive environments, integrated into a conveying device with a feed pump and motor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional flow meters are used to measure coating material flow rates, then flow measurement can be achieved, but the flow meters are subject to high wear when handling abrasive materials
Solution Approach 1:
The patent replaces traditional mechanical flow meters with a magnetic field-based sensor system. The sensor detects the position of a magnetically coupled drive element through a non-magnetic wall, eliminating direct mechanical contact between the sensor and abrasive coating materials. This substitution of mechanical measurement with magnetic field detection resolves the wear issue while maintaining measurement capability.
2Measurement precision
If traditional flow meters are used in explosive environments with solvent-containing lacquers, then flow measurement can be achieved, but the device cannot function safely in such environments
Solution Approach 1:
The patent replaces electrical or mechanical flow measurement systems with a magnetic field-based detection system. The magnetic field penetrates the non-magnetic wall to detect the position of the drive element without requiring electrical components inside the hazardous zone. This eliminates ignition sources while maintaining measurement functionality in explosive environments.
Solution Approach 2:
The patent introduces a non-magnetic wall as an intermediary barrier that isolates the sensor from the hazardous coating material environment. The magnetic field can penetrate this barrier to detect the drive element position without direct contact, protecting the sensor from exposure to explosive solvents while enabling continuous measurement.
3Reliability
If contactless measurement is implemented using a magnetic sensor system, then wear-free operation is achieved, but the device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single magnetic sensor system: position detection, flow rate calculation, and wear-free operation. The sensor unit combines a magnetic sensor, evaluation unit, and communication interface that work together to provide comprehensive measurement capabilities without requiring separate mechanical components, thereby managing complexity through functional integration.
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 accurate, wear-free measurement of coating material flow rates in various environments, including those with explosive risks, and can handle different types of materials like water, lacquers, adhesives, and casting compounds without the limitations of traditional flow meters.
Implementation Method 1
a magnetic position transmitter (1), which is developed in such a way that it can follow the magnetic object (20), that it can be moved along the contact electrode (34)
Data Source
AI summary
The sensor according to the invention for detecting the position of a movable magnetic object includes a resistance track and a contact electrode arranged thereon. Moreover the sensor includes a magnetic position transmitter, which is developed in such a way that it can follow the magnetic object, that it can be moved along the contact electrode and through which the contact electrode can be brought into contact with the resistance track.