Magnetic Position Sensor Housing for Extreme Environments
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Position monitoring devices for extreme environments, such as high-pressure and caustic conditions in hydrocarbon production and CO2 sequestration, are costly due to the limitations of existing sensor technologies.
Innovation Solution
A position monitoring system comprising a tubular with a cavity housing a magnet and a sensor that isolates the sensor from environmental parameters using a housing with low magnetic permeability, allowing it to detect the magnetic field of a magnet without interference, while the tubular with high magnetic permeability minimizes material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional sensors are used in extreme environments (high pressure, caustic fluids), then position monitoring can be achieved, but the cost becomes quite expensive
Solution Approach 1:
The system divides the monitoring function into two separate components: a magnet attached to the movable member and a sensor housed in a protected housing. This segmentation allows the sensor to remain in a protected environment while the magnet operates in the extreme environment, reducing the need for expensive specialized sensors.
Solution Approach 2:
A magnetic field serves as an intermediary between the magnet and the sensor, allowing position information to be transmitted through the tubular wall without requiring direct contact or exposing the sensor to the extreme environment. This intermediary approach enables standard sensors to be used while maintaining reliability.
2Measurement precision
If the tubular wall is made of non-magnetic material to allow magnetic field sensing, then sensor accuracy is maintained, but material costs increase
Solution Approach 1:
The housing material is selected with specific local properties (low magnetic permeability) only where needed for magnetic field transmission, while the rest of the system can use standard materials. This localized application of special material properties reduces overall material costs while maintaining sensing accuracy.
Solution Approach 2:
The system uses composite construction with a housing made of non-magnetic material (such as aluminum or plastic) that allows magnetic field penetration, combined with a magnetic seal or flange connection to the magnetic tubular. This composite approach enables the use of inexpensive magnetic tubular material while maintaining measurement precision through the non-magnetic housing.
3Device complexity
If the sensor is exposed to the magnetic field directly without a housing, then sensing is simplified, but the sensor becomes vulnerable to environmental damage
Solution Approach 1:
The housing acts as an intermediary structure that physically protects the sensor from environmental damage while allowing the magnetic field to pass through. This intermediary approach resolves the contradiction by providing protection without significantly increasing complexity.
Solution Approach 2:
The housing can be constructed from thin-walled non-magnetic material that provides environmental protection while maintaining magnetic field permeability. This thin-film approach minimizes the added complexity and weight while ensuring sensor reliability in harsh environments.
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 system effectively monitors position with reduced material costs and enhanced durability against environmental pressures and caustic fluids, maintaining sensor accuracy and reliability.
Implementation Method 1
A sensor fixed relative to the other of the tubular and the member is sensible of a magnetic field of the magnet
Implementation Method 2
The housing 42 is made of a material having a relatively low magnetic permeability so that a magnetic field of the magnet 34 can be sensed through walls 46 of the housing 42
Data Source
AI summary
A position monitoring system includes a tubular with a cavity formed therein, a magnet movable relative to the tubular, and a sensor sensible of a magnetic field of the magnet. A housing positioned within the cavity sealably isolates the sensor from environmental properties while permitting the sensor to sense the magnetic field of the magnet.