Self-locating Magnetic Interface for Gas Meter Sensors
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Solution Overview
Problem
Manufacturing inaccuracies and tolerances in non-contact interfaces for gas meters can lead to alignment issues and increased assembly costs, affecting the accuracy and reliability of flow measurement.
Innovation Solution
A self-locating magnetic interface design that incorporates 'play' or 'float' features, utilizing magnets and motion-transfer units to ensure proper alignment and conversion of mechanical movement into digital signals for precise flow measurement, eliminating the need for end-user intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If non-contact interface is used to convert mechanical movement to digital signals, then physical integrity of gas meter is maintained, but manufacturing inaccuracies and tolerances cause alignment issues and increased assembly costs
Solution Approach 1:
A magnetic coupling mechanism is introduced as an intermediary between the mechanical counter and the electronic sensor. The magnetic field acts as a mediator that transfers motion information without requiring direct mechanical contact or precise alignment between the mechanical and electronic components, thus resolving the alignment precision issue while maintaining physical integrity.
Solution Approach 2:
The patent replaces direct mechanical coupling with a magnetic coupling system. Instead of requiring precise mechanical alignment between the counter shaft and sensor, the magnetic field enables non-contact transmission of motion data, eliminating alignment sensitivity while preserving the mechanical-to-digital conversion function.
2Ease of manufacture
If non-contact interface is used for flow measurement, then manufacturing costs are reduced, but alignment issues affect measurement accuracy and reliability
Solution Approach 1:
The magnetic coupling serves as an intermediary that decouples the mechanical and electronic systems, allowing each to be manufactured independently with standard tolerances. The magnetic field ensures consistent signal transmission regardless of minor positional variations, maintaining measurement accuracy while simplifying manufacturing.
Solution Approach 2:
The patent changes the coupling parameter from mechanical contact (requiring precise position) to magnetic field interaction (tolerant to position variations). This parameter change allows the system to maintain measurement precision across different manufacturing tolerances and assembly conditions.
3Measurement precision
If precise alignment is required for non-contact interface, then measurement accuracy is improved, but assembly complexity and end-user intervention are increased
Solution Approach 1:
The magnetic coupling mechanism acts as a self-aligning intermediary that automatically accommodates misalignment during assembly. The magnetic field naturally adjusts to maintain coupling even with varying positions, eliminating the need for precise alignment procedures or specialized assembly tools.
Solution Approach 2:
The magnetic coupling system is self-aligning and self-adjusting, requiring no end-user intervention for alignment during installation. The system automatically ensures proper signal transmission through the magnetic field, making the assembly process simpler and more user-friendly while maintaining measurement accuracy.
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 proposed design enhances the fit-and-function of non-contact interfaces, reducing alignment issues and assembly complexities, ensuring accurate and reliable flow measurement without requiring special setup or attention, thus improving the overall performance and efficiency of gas meters.
Implementation Method 1
These embodiments may take advantage of underlying properties, like magnetics, that the devices use to convert mechanical movement into signals that form the basis for measurement of flow.
Data Source
AI summary
A sensor unit that is configured to improve the non-contact, magnetic interface on a gas meter. The configurations may include a pair of magnets that co-rotate in response to a magnet internal to the gas meter. At least one of the magnets may also move longitudinally in proximity to the internal magnet. This feature aligns the magnets with one another to ensure proper magnetic coupling with the internal magnet.