Eccentric Screw Pump Stator With Vulcanized Sensor Integration
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Solution Overview
Problem
Current methods for data recording in progressive cavity pumps are costly, require additional manufacturing effort, and are prone to sensor detachment, leading to undetected faults and increased manufacturing complexity, while also making it easier for counterfeit stators to be produced.
Innovation Solution
Integrating sensors inseparably into the elastomer stator during its manufacturing process, preferably by vulcanization, allowing for direct monitoring and reducing manufacturing effort and sensor costs, while enhancing authentication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If sensors are retrofitted to the stator after manufacturing, then data recording capability is achieved, but manufacturing effort and cost increase significantly
Solution Approach 1:
The patent applies preliminary action by integrating the sensor into the stator during the vulcanization process itself, rather than retrofitting it afterward. The sensor is positioned and embedded in the elastomer material before final curing, allowing the vulcanization to bond the sensor permanently to the stator structure. This eliminates subsequent machining and installation steps, directly reducing manufacturing effort while ensuring reliable data recording capability.
2Measurement precision
If expensive industrial sensors are used for data recording, then measurement accuracy is improved, but cost increases significantly
Solution Approach 1:
The patent employs inexpensive temperature sensors (such as NTC sensors) that are integrated directly into the stator during vulcanization. These sensors provide sufficient measurement accuracy for monitoring pump operation and detecting faults. By using cheaper sensor alternatives and eliminating the need for expensive industrial-grade components, the solution significantly reduces cost while maintaining adequate measurement precision for the application requirements.
3Ease of operation
If sensors are anchored only in the elastomer material, then radial expansion movements are not impeded, but sensor detachment risk increases
Solution Approach 1:
The patent merges the sensor attachment with the stator manufacturing process by vulcanizing the sensor directly into the elastomer material. The sensor becomes an integral part of the stator structure during curing, creating a permanent bond that maintains both radial expansion capability and attachment reliability. The elastomer material itself serves as the bonding medium, eliminating the need for separate anchoring mechanisms that would restrict movement.
4Ease of manufacture
If sensors are integrated into the stator, then manufacturing effort is reduced, but sensor detachment during operation becomes a concern
Solution Approach 1:
The patent utilizes the phase transition of the elastomer material during vulcanization (from uncured to cured state) to permanently bond the sensor to the stator. The vulcanization process transforms the elastomer from a soft, moldable state to a hardened, cross-linked structure that encapsulates and secures the sensor. This phase transition creates an irreversible bond that prevents sensor detachment during operation while maintaining the manufacturing simplicity of integration during the uncured state.
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
Facilitates cost-effective, reliable data recording and detection of faults, while preventing sensor detachment and counterfeit stator production, thus extending pump lifespan and improving manufacturing efficiency.
Implementation Method 1
The stator is vulcanized into a preferably metallic support tube
Implementation Method 2
the at least one sensor is vulcanized completely or at least partially or over a single surface, namely at its edge or at the transition between the stator (i.e., the lining) and the support tube
Data Source
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AI summary
Eccentric screw pump with a screw-shaped rotor and a stator made of an elastomer material in which the rotor rotates, forming several pump chambers, wherein the stator is vulcanized into a preferably metallic support tube, wherein the stator has at least one sensor which is inseparably connected to the stator - namely vulcanized into it.