Reed Sensor Module for Hydraulic Valve Position Detection
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Solution Overview
Problem
Existing devices for end position detection in lift valves are complex, expensive, and require additional sensors for detecting spindle positions beyond end positions, with magnetic elements being susceptible to chemical resistance issues.
Innovation Solution
A compact and inexpensive solution using reed or optical sensors arranged on a printed circuit board, where additional sensors are switched off as needed, allowing for flexible adaptation to different valve sizes and positions, with a magnetic element protected by a cap to prevent mechanical damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional sensors are added to detect intermediate spindle positions, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The sensor module is designed with multiple reed sensors that can detect both end positions and intermediate positions of the spindle. The same sensor module structure serves multiple detection functions by simply activating or deactivating specific reed sensors, eliminating the need for different sensor modules for different detection requirements.
Solution Approach 2:
The sensor module allows dynamic configuration of detection points by selectively activating or deactivating reed sensors through switches. This enables the system to adapt between detecting only end positions or also detecting intermediate positions without physical reconfiguration.
2Measurement precision
If magnetic elements with high magnetic force are used, then measurement precision is improved, but chemical resistance deteriorates
Solution Approach 1:
A non-magnetic cap is introduced as an intermediary protective layer between the magnetic element and the corrosive medium. This cap allows the magnetic element to maintain its high magnetic force for accurate detection while being protected from chemical corrosion, thus resolving the contradiction between detection sensitivity and chemical resistance.
3Adaptability or versatility
If a single sensor module is used for various valve sizes, then adaptability is improved, but manufacturing precision requirements increase
Solution Approach 1:
The sensor module is designed as a universal component that can be applied to different valve sizes and stroke lengths. By incorporating multiple reed sensors at different positions and allowing selective activation, the same module adapts to various application requirements without requiring custom manufacturing for each valve type.
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 precise and cost-effective end position detection in lift valves, reducing manufacturing and storage costs by using a single sensor module for various valve sizes and positions, while ensuring the magnetic element's durability and maintaining high magnetic properties.
Implementation Method 1
A magnetic element is arranged on part of the valve spindle inside the control head, which is guided past a first reed sensor in the first spindle position and a second reed sensor in the second spindle position during the displacement process of the spindle. The reed sensors detect the spindle positions.
Implementation Method 2
Instead of reed sensors that detect magnetic elements, optical sensors that detect detection elements can also be provided
Data Source
Figure 1~2
Figure 3
AI summary
The device has a magnet element (28) e.g. axially magnetized permanent magnet, directed towards respective reed sensors during displacement of a spindle (20) in two respective positions. The spindle is axially displaceable between the positions relative to a distance (H1). The reed sensors detect the spindle positions such that the reed sensors are arranged on a printed circuit board (30) in a sensor module. The reed sensors are switched off using switches i.e. dual in-line (DIP)-switches. The board is arranged parallel to the spindle and the reed sensors.