Non-Contact Valve Position Sensor Using Hall Sensors
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Solution Overview
Problem
Existing electrical position determination devices for process valves are large, costly, complex to assemble, difficult to clean, and limited in application due to the need for multiple adapters and poor sealing/shielding, especially when used with various valve types and lifts.
Innovation Solution
The device separates electronics from moving parts, using a non-contact position detection method with a spring housed within the device, allowing for a compact design that can accommodate a wide range of valve types without adapters, with Hall sensors and a differential measurement system for precise positioning and protection against mechanical damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a linear potentiometer is used for position detection, then the position can be detected, but the device becomes relatively large and complex
Solution Approach 1:
The patent replaces the mechanical contact-based linear potentiometer with a non-contact magnetic field detection system using Hall sensors. This substitution eliminates mechanical wear, reduces device complexity, and maintains measurement precision by detecting the position of a magnet attached to the actuating means through magnetic field variations.
Solution Approach 2:
The patent extracts the spring from the housing structure and mounts it directly on the actuating means. This separation allows the spring to move with the actuating means without requiring the housing to provide guidance, simplifying the overall device structure and reducing complexity.
2Adaptability or versatility
If multiple adapters are mounted for different valve types, then the device can accommodate various valve lifts, but the manufacture becomes cost-intensive and assembly complex
Solution Approach 1:
The patent achieves universality by designing a standardized mounting interface and non-contact detection system that can accommodate various valve types without requiring multiple adapters. The magnetic field detection method and spring-mounted actuating means provide a flexible solution that adapts to different valve lifts through software configuration rather than hardware modification.
Solution Approach 2:
The patent uses parameter changes in the magnetic field detection system to adapt to different valve types. By varying the detection range, sensitivity, and evaluation parameters of the Hall sensors, the device can accommodate various valve lifts and types without physical modifications or additional adapters.
3Force
If the spring is mounted on the housing, then the spring can exert force, but the housing must provide guidance increasing complexity
Solution Approach 1:
The patent extracts the spring from the housing structure and mounts it directly on the actuating means. This allows the spring to move together with the actuating means without requiring the housing to provide guidance, thereby reducing the complexity of the housing structure while maintaining the necessary spring force.
Solution Approach 2:
The patent segments the force application system by separating the spring mounting from the housing. The spring is independently mounted on the actuating means, creating a modular arrangement where the force-generating component is decoupled from the structural housing, simplifying both components.
4Volume of moving object
If electronics are integrated with moving parts, then the device is compact, but sealing and shielding become difficult
Solution Approach 1:
The patent extracts the electronics (Hall sensors and evaluation circuitry) from the moving parts and places them in a stationary position within the housing. This separation maintains device compactness while significantly improving sealing and shielding, as the electronics are no longer exposed to the dynamic environment and mechanical movements.
Solution Approach 2:
The patent segments the device into moving components (actuating means with spring and magnet) and stationary components (housing with electronics). This segmentation allows the moving parts to be sealed and protected independently, while the electronics remain in a protected stationary environment, improving overall reliability.
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 enhances sealing, simplifies cleaning and assembly, expands application to various valve types, reduces manufacturing costs, and provides robust protection for electronic components, while maintaining precise position detection and compactness.
Implementation Method 1
The position detection device has two measuring points, at each of which a pair of two Hall sensors is arranged
Data Source
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AI summary
The present invention relates to an electric position determining apparatus (1) for installation on a valve having a housing (2) and an actuating means (3) which is arranged movably in said housing (2) and is loaded with a spring force by means of a spring (5) which is arranged on the housing (2), in such a way that, when it is installed on a valve, it is pressed onto a drive means of the valve and can follow its movements in the valve. Here, a position determining device (6) is provided which detects the position of the actuating means (3). According to the invention, a position determining device (6) is provided which detects the position of the actuating means (3) contactlessly. In addition, the spring (5) is arranged in the housing. This embodiment of the position determining apparatus makes it possible to provide an apparatus which can be operated on a wide variety of valves without relatively great conversion work, and which is particularly satisfactory to clean and to maintain and to commission.