Valve Stem Displacement Sensor Using Flux Concentrators
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current position sensing and displacement measurement systems for valve stems are complex, power-intensive, and require multiple Hall effect sensors, making them expensive, difficult to maintain, and not suitable for compact applications.
Innovation Solution
A system using a pair of strategically positioned Hall effect sensors or magneto-resistive sensors with a flux concentrator and a microcontroller-based processing circuit to accurately measure valve stem displacement with reduced power consumption, allowing for compact and cost-effective construction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple Hall effect sensors are used for position sensing, then measurement accuracy is improved, but device complexity and power consumption increase
Solution Approach 1:
The patent combines multiple sensing functions into a single Hall effect sensor by using magnetic flux concentrators that direct flux from multiple magnets to one sensor, eliminating the need for multiple sensors while maintaining measurement accuracy across the full range of motion
Solution Approach 2:
The patent introduces magnetic flux concentrators as intermediary elements that mediate between the magnets and the Hall effect sensor, channeling and concentrating magnetic flux to improve sensor output signal strength and enable accurate position detection with fewer sensors
2Measurement precision
If multiple Hall effect sensors are used for position sensing, then measurement accuracy is improved, but power consumption increases
Solution Approach 1:
The patent combines multiple sensing functions into a single Hall effect sensor that is activated only during valve stem movement, replacing multiple continuously-powered sensors with one intermittently-powered sensor, thereby significantly reducing overall power consumption
Solution Approach 2:
The patent implements periodic activation of the Hall effect sensor, powering it on only during valve stem movement and turning it off during idle periods, which reduces average power consumption while maintaining measurement accuracy when needed
3Measurement precision
If conventional position sensing systems are used, then position measurement is achieved, but the system becomes expensive and difficult to maintain
Solution Approach 1:
The patent extracts and eliminates unnecessary components from conventional position sensing systems, removing multiple sensors, complex signal processing circuits, and redundant structural elements, retaining only the essential Hall effect sensor and flux concentrators to reduce cost and simplify maintenance
Solution Approach 2:
The patent employs inexpensive magnetic flux concentrators made from readily available materials that can be easily replaced if needed, substituting for expensive precision sensors and complex electronic components, thereby reducing overall system cost and simplifying maintenance
4Measurement precision
If conventional position sensing systems are used, then position measurement is achieved, but the system is not suitable for compact applications
Solution Approach 1:
The patent nests the magnetic flux concentrators within the existing valve assembly structure, integrating the sensing system into the available space without requiring additional external components or increasing overall system volume
Solution Approach 2:
The patent utilizes the magnetic field dimension rather than physical contact or mechanical linkages, allowing position sensing to occur through the magnetic flux field without requiring physical space for additional sensing mechanisms, thereby enabling compact integration
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 system achieves accurate and reliable position sensing and displacement measurement with reduced energy consumption, enabling simple, sturdy, and versatile applications in various settings, including valve calibration and health monitoring.
Implementation Method 1
position sensing and displacement measurement systems utilize Hall effect sensors to determine the position of a magnet in 3-dimensional space
Implementation Method 2
Each of the sensors utilizes a flux concentrator which is configured to receive and direct the magnetic flux of the magnet to the sensors
Implementation Method 3
A system using a pair of strategically positioned Hall effect sensors or magneto-resistive sensors with a flux concentrator
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
A system for measuring displacement of a valve stem of a valve assembly is disclosed in accordance with an embodiment of the present disclosure. The system includes housing, a magnet and at least one pair of sensors. The valve stem slides along the wall of the housing. The magnet is mounted on the valve stem and moves between two pre-determined positions defined along an axis of motion of the valve stem within the housing in response to displacement of the valve stem for facilitating change in magnetic flux associated with the magnet. The at least one pair of sensors are mounted in the housing, wherein each of said sensors is disposed on either side of the axis for determining displacement of the magnet based on change in the magnetic flux caused by motion of the magnet.