Universal Sensor Housing With Interchangeable Flow Cell Heads
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Solution Overview
Problem
Existing flow cells are typically single-use and limited to a specific type of measurement, leading to a proliferation of sensors and complex logistics in continuous manufacturing processes, where continuous monitoring of process streams is crucial for maintaining process efficiency and product quality.
Innovation Solution
A universal sensor system with a static housing and interchangeable sensor heads that can perform multiple measurements, allowing for a single wire connection and easy swapping of sensor heads and flow cells without disconnecting cables, integrating sensors for conductivity, temperature, pressure, and light measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple separate sensors are used for different measurements, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple separate sensors (optical sensor, conductivity sensor, temperature sensor, pressure sensor) into a single integrated sensor head that can perform all measurements simultaneously. This merging approach maintains the measurement precision of individual sensors while reducing device complexity by eliminating the need for multiple separate sensor units and their associated cabling.
Solution Approach 2:
The sensor head is designed as a universal multi-functional device that can perform multiple types of measurements (optical, conductivity, temperature, pressure) through a single interface. This multi-functionality allows one sensor head to replace multiple specialized sensors, thereby reducing overall system complexity while maintaining all necessary measurement capabilities.
2Adaptability or versatility
If multiple sensors and cables are used, then measurement capabilities are improved, but ease of operation deteriorates
Solution Approach 1:
By merging multiple sensors and their connections into a single integrated sensor head with a unified cable interface, the system simplifies installation and operation. Users only need to connect one cable instead of managing multiple separate connections, significantly improving ease of operation while retaining all measurement capabilities.
Solution Approach 2:
The universal sensor head design allows a single device to perform multiple measurement types, eliminating the need for users to select and connect different specialized sensors for different measurements. This multi-functionality greatly enhances ease of operation while maintaining full adaptability for various measurement needs.
3Measurement precision
If single-use flow cells are used for each measurement type, then measurement precision is maintained, but productivity decreases
Solution Approach 1:
The patent integrates multiple measurement functions into a single flow cell that can simultaneously or sequentially perform optical, conductivity, temperature, and pressure measurements. This eliminates the need to replace flow cells between different measurement types, maintaining measurement precision while significantly improving productivity by reducing setup time and cell replacement frequency.
Solution Approach 2:
The flow cell is designed as a universal multi-functional platform that supports all measurement types through a single interface. This multi-functionality allows continuous monitoring of multiple parameters without requiring separate single-use cells for each measurement, thereby maintaining precision while enhancing productivity through reduced operational complexity.
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
Simplifies data collection and logistics by enabling a single device to perform multiple measurements, reducing the need for multiple sensors and cables, and ensuring correct pairing of sensor heads and flow cells, thereby improving process efficiency and product quality in continuous manufacturing processes.
Implementation Method 1
a sensor head including a light source and an array of electrical contacts
Implementation Method 2
a lower housing including a flow cell mount and a measurement photodiode
Data Source
AI summary
Sensor systems, and flow cells for use with them, which can provide for a universal sensor housing. The senor housing includes a first section which is designed to remain statically in position and a selectable sensor head that may be swapped out as necessary. The specific head is selected based on the types of measurement to be performed at the sensor location and the sensor head can integrate with the housing so only a single wire connection needs to be made to obtain all data from the housing.