Steam Trap Sensor Assembly Insulation and Sealing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing steam trap systems lack an efficient sensor assembly structure, leading to poor air-tightness and measurement accuracy, especially when multiple sensors are used, resulting in steam leakage and condensate water interference.
Innovation Solution
A steam trap system with a housing containing a feeding hole, discharging hole, and an opening for sensor installation, featuring an insulation member to maintain air-tightness and a cover to protect the sensor terminal, along with condensation guide pins and a solenoid valve with a mesh socket to minimize condensate water contact and ensure accurate measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Difficulty of detecting and measuring
If sensors are installed inside the housing to measure water level or temperature, then measurement capability is improved, but air-tightness deteriorates due to lack of specific assembly structure
Solution Approach 1:
The sensor assembly structure is segmented into multiple functional components: insulation member, cover, sealing member, and fastening member. Each component performs a specific function (insulation, sealing, protection, fixation) to collectively resolve the contradiction between measurement capability and air-tightness.
Solution Approach 2:
The sensor is nested within the insulation member, which is in turn nested within the housing opening. The cover is then installed over the insulation member to seal the assembly. This nested structure allows the sensor to be installed while maintaining air-tightness through multiple layers of protection and sealing.
2Measurement precision
If multiple sensors are used to enhance measurement accuracy, then measurement precision is improved, but assembly complexity and air-tightness maintenance become more difficult
Solution Approach 1:
The insulation member and cover structure serve multiple functions simultaneously: they provide thermal insulation for all sensors, maintain air-tightness through the sealing member, protect sensor terminals, and facilitate assembly through the fastening member. This universal structure can accommodate multiple sensors without proportionally increasing complexity.
3Ease of manufacture
If sensors are exposed inside the housing, then installation is simplified, but condensate water contact increases reducing measurement accuracy
Solution Approach 1:
The insulation member acts as an intermediary between the sensor and the condensate water environment. It provides thermal insulation and, when combined with the cover and sealing member, creates a protected environment that prevents condensate water contact while still allowing the sensor to perform its measurement function accurately.
4Device complexity
If no insulation member is used for sensor installation, then assembly is simpler, but air-tightness and thermal insulation are compromised
Solution Approach 1:
The insulation member merges multiple functions into a single component: thermal insulation, structural support for the sensor, mounting surface for the cover, and integration with the sealing member. This consolidation maintains air-tightness and thermal insulation without proportionally increasing assembly complexity.
Data Source
AI summary
A steam trap system is provided which can improve efficiency of sensor assembly and air-tightness. The steam trap system includes: a housing that includes a feeding hole for feeding steam, a discharging hole for discharging condensate water, and an opening; at least one sensor that is disposed inside the housing via the opening; an insulation member that is disposed in the opening to maintain air-tightness and to which the sensor is fixed to expose a terminal; and a cover that is disposed in the insulation member to cover the terminal.