Segmented Rubber Mixer Temperature Sensor with Pneumatic Cooling
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Solution Overview
Problem
Existing temperature sensors in Banbury-type internal mixers are multi-part and require full replacement when only the measurement part is defective, leading to high replacement costs and inaccurate temperature readings due to inertia issues during mixing cycles.
Innovation Solution
A temperature sensor design featuring a fixed and removable part with integrated compressed air cooling, allowing only the removable part with temperature measuring elements to be replaced, and using a blowing stem for quick cooling to ensure accurate initial temperature readings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire temperature sensor is replaced when only the measurement part is defective, then the sensor reliability is maintained, but the replacement cost increases significantly
Solution Approach 1:
The temperature sensor is divided into a fixed part (housing, mounting structure) and a removable part (measurement elements, contact tip). This segmentation allows only the removable part to be replaced when defective, rather than replacing the entire sensor assembly, thereby reducing replacement costs while maintaining reliability.
Solution Approach 2:
The invention allows discarding only the removable part containing the measurement elements when they wear out or fail, while recovering and reusing the fixed part. This selective replacement approach reduces material loss and replacement costs compared to replacing the entire sensor.
2Device complexity
If traditional temperature sensors are used, then the sensor structure is simple, but the temperature measurement accuracy is poor during the first seconds of mixing cycles due to inertia
Solution Approach 1:
A compressed air blowing system is integrated into the sensor, using pneumatic flow to rapidly cool the removable part and measurement elements at the start of mixing cycles. This pneumatic cooling mechanism enables accurate temperature measurements from the beginning of the cycle by counteracting the thermal inertia of the sensor components.
3Strength
If the sensor components are permanently joined together, then the sensor robustness is improved, but the ease of repair deteriorates as the entire sensor must be replaced
Solution Approach 1:
The sensor is segmented into a fixed part and a removable part with specific connection interfaces. The fixed part provides structural robustness and stability during operation, while the removable part can be easily detached and replaced. This segmentation resolves the contradiction by allowing robust construction without permanent joining, enabling easy repair through component replacement.
Solution Approach 2:
The connection between the fixed part and removable part is designed to be dynamic rather than static - it provides stable mechanical coupling during operation but allows easy disassembly for replacement. This dynamic design enables the sensor to maintain robustness during use while facilitating simple repair operations.
4Measurement precision
If the removable part is quickly cooled with compressed air, then the temperature measurement accuracy is improved at the start of mixing cycles, but the device complexity increases
Solution Approach 1:
The compressed air blowing system serves multiple functions: it rapidly cools the removable part for accurate temperature measurement, provides a means to eject the removable part during replacement, and helps clean the measurement elements. This multi-functionality justifies the added complexity by providing measurement precision and operational benefits beyond simple cooling.
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
This design reduces replacement costs, enhances sensor robustness, and provides accurate temperature measurements from the start of mixing cycles by quickly cooling the removable part with compressed air, minimizing the financial investment and ensuring reliable mixing quality monitoring.
Implementation Method 1
The blowing stem extends along the conduit of the body from the access end, where the blowing stem enters the body, and terminates at an outlet end disposed in the conduit of the removable part so that compressed air exits the blowing stem and passes uninterruptedly through the temperature measuring element(s) at the contact end
Data Source
AI summary
A temperature sensor (10) for measuring a temperature of a mixture being mixed in an internal mixer includes a fixed part having a substantially cylindrical body (12) and a removable part (16) of domed shape arranged inside a conduit of the body. The temperature sensor also includes a blowing stem (14) in communication with a source of compressed air that extends along a conduit (12c) of the body and terminates at an outlet end (14a) disposed in the removable portion (16), whereby the compressed air exits the blowing stem (14) and passes uninterruptedly through a temperature measuring element or elements at a contact end (16b) of the removable portion. A combination of an internal mixer and a temperature sensor for measuring a temperature of a mixture being mixed in the internal mixer is also disclosed.