Sensorized Support Assembly for Water Ingress Detection
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Solution Overview
Problem
Existing support assemblies in the food industry face challenges with hygiene-related issues due to aggressive washing fluids, which can compromise sealing devices and manual inspection inefficiencies, and temperature monitoring limitations below 80°C.
Innovation Solution
A sensorized support assembly with a cup-shaped cover featuring a sensor to monitor relative humidity and temperature, utilizing a bayonet coupling for error-proof mounting and grooves to direct water to the sensor, ensuring reliable detection of water ingress and temperature control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection is performed by removing the cover to check for water ingress, then water ingress can be detected, but significant time is lost and risk of water ingress during inspection increases
Solution Approach 1:
A sensor is installed inside the cover to perform preliminary detection of water ingress before manual inspection is needed. The sensor continuously monitors for the presence of water, allowing operators to be alerted immediately without needing to manually remove and reassemble the cover for inspection.
Solution Approach 2:
The manual mechanical inspection process of removing and reassembling the cover is replaced by an electronic sensor-based detection system. The sensor automatically detects water presence through electrical or optical means, eliminating the need for physical disassembly and reducing inspection time to near-zero while maintaining or improving detection reliability.
2Reliability
If the cover is removed for manual inspection, then water ingress can be detected, but the risk of incorrect mounting and new water ingress cannot be eliminated
Solution Approach 1:
The sensor is pre-installed and continuously monitors for water ingress, allowing detection to occur without any removal of the cover. This eliminates the opportunity for incorrect mounting and subsequent water ingress that occurs during manual inspection procedures.
Solution Approach 2:
The mechanical disassembly and reassembly process is replaced by an electronic sensing system that can detect water through the intact cover structure. This substitution eliminates the harmful effect of potential incorrect mounting and associated water ingress risks entirely.
3Measurement precision
If temperature monitoring is performed using external thermocouple, then temperature can be measured, but hygiene standards are not compatible
Solution Approach 1:
The temperature sensor is nested within the cover structure itself, which is a hygiene-compliant component. The sensor is integrated into the existing sanitary design of the cover, allowing temperature measurement without compromising hygiene standards. This nested integration allows the measurement function to be embedded within the hygiene-certified structure.
Solution Approach 2:
The external thermocouple measurement system is replaced by an integrated sensor that can operate within the hygiene-compliant cover structure. The sensor uses electrical or optical fields to measure temperature without requiring external mechanical connections that would compromise hygiene standards.
4Reliability
If sealing devices are added to prevent washing fluid ingress, then bearing protection is improved, but sealing device failure under high pressure remains a risk
Solution Approach 1:
The cover structure serves as an intermediary protective element between the high-pressure washing environment and the bearing unit. The cover is designed to withstand the mechanical stress of high-pressure washing, absorbing and distributing the pressure loads before they reach the more sensitive sealing devices and bearing components.
Solution Approach 2:
The cover structure provides beforehand cushioning by being positioned as the first line of defense against high-pressure washing jets. It absorbs and mitigates the impact of pressure waves and fluid forces before they can directly affect the sealing devices, reducing the stress and failure risk on these critical components.
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 sensorized support assembly effectively reduces manual inspection time and risk of water ingress, while ensuring temperature compliance by accurately monitoring humidity and temperature, with interchangeable and long-lasting components.
Implementation Method 1
The cover (20) is provided with a sensor (40) for monitoring the relative humidity inside the cover (20)
Implementation Method 2
a sensor (40) for monitoring the relative humidity inside the cover (20) and, where applicable, the temperature
Implementation Method 3
utilizing a bayonet coupling for error-proof mounting and grooves to direct water to the sensor
Data Source
Figure 1
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Figure 3
AI summary
Support assembly (1) having a central axis (X) and provided with: - a flanged casing (10) having a through-seat (15) and a mounting seat (11) axially inside the through-seat, - a cover (20) provided with a coupling portion (24) for closing the through-seat of the casing in a fluid-tight manner, and an annular wall (23), and - a bearing unit (30) seated inside the mounting seat, in which - the cover is provided with a sensor (40) for monitoring the relative humidity inside the support assembly and in that - the sensor is assembled in a support portion (26) of the cover positioned inside the annular side wall, which corresponds to a lower portion (20') of the cover once the cover has been mounted on the casing, where any fluid that has penetrated the cover will accumulate under the effect of gravity.