Viscometer Magnetic Alignment Reduces Friction Heating
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Solution Overview
Problem
Conventional rotational viscometers require several tens of seconds to a minute to achieve a stable equilibrium for viscosity measurement, leading to increased sample temperature due to friction, which impairs measurement accuracy and efficiency, especially in high-throughput sample-manufacturing facilities.
Innovation Solution
A viscometer design featuring a stepper motor, strain gauge unit, and magnetic alignment for minimal friction, allowing for rapid startup and equilibrium within one second, enabling accurate viscosity measurement with reduced temperature increase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional rotational viscometers are used to measure viscosity, then measurement can be performed, but the measurement time is long (several tens of seconds to one minute) and sample temperature increases due to friction
Solution Approach 1:
The patent replaces the conventional mechanical spring-based torque measurement system with a magnetic field-based measurement system. The rotor is equipped with a magnet, and the stator contains a coil that detects changes in magnetic flux as the rotor rotates. This substitution eliminates mechanical friction between the rotor and sample, allowing for rapid acceleration and measurement within one second while maintaining viscosity measurement accuracy through electromagnetic detection of rotational equilibrium.
2Measurement precision
If conventional rotational viscometers rotate the rotor for equilibrium, then viscosity measurement is enabled, but sample temperature increases due to friction between rotor and sample
Solution Approach 1:
The patent eliminates mechanical contact friction by using a magnetic field-based torque measurement system. The rotor with magnet interacts with the stator coil through magnetic coupling, allowing torque detection without physical contact between the rotor and sample. This non-contact measurement approach prevents frictional heating while maintaining measurement accuracy, enabling rapid measurements that complete before significant temperature rise occurs.
Solution Approach 2:
The patent employs periodic rotation of the rotor at controlled speeds to achieve equilibrium quickly. The rotor rotates periodically to allow the magnetic field to stabilize and the viscous forces to reach equilibrium within one second. This periodic action enables rapid sampling while minimizing the total time the rotor is rotating, thereby reducing cumulative frictional heating of the sample.
3Productivity
If rapid measurement is implemented to reduce time loss, then measurement speed increases, but measurement accuracy may deteriorate due to insufficient equilibrium time
Solution Approach 1:
The magnetic field-based measurement system enables instantaneous detection of rotational equilibrium without the delays inherent in mechanical systems. The stator coil detects changes in magnetic flux in real-time as the rotor accelerates and reaches equilibrium, allowing the system to determine viscosity accurately within one second. This electromagnetic detection method provides both the speed needed for high throughput and the precision required for accurate measurement.
Solution Approach 2:
The patent incorporates a feedback mechanism where the controller continuously monitors the signal from the stator coil, which reflects the rotational speed and equilibrium state of the rotor. Based on this feedback, the controller adjusts the rotation speed and determines when equilibrium has been reached, enabling rapid yet accurate viscosity measurements. The feedback loop ensures that measurements are completed as quickly as possible while maintaining the necessary equilibrium conditions for accuracy.
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 viscometer achieves high-accuracy viscosity measurements in under one second, significantly reducing sample temperature rise and enhancing measurement efficiency for high-throughput applications.
Implementation Method 1
a strain gauge unit (74) including a cantilever (742) deformed by a rotation of the motor body (711) in the first direction
Implementation Method 2
A viscometer design featuring a stepper motor, strain gauge unit, and magnetic alignment for minimal friction
Data Source
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AI summary
A viscosity measurement unit (7) includes a first stage (33) having a first surface (33a), a second stage (81) having a second surface (811a) and configured to rotate with the second surface (811a) which is opposed and in proximity to the first surface (33a), a motor (71) including a motor body (711) and a shaft (713) that is an output shaft of the motor body (711) and configured to rotate synchronously with the second stage (81), a fixed member (75) arranged to rotatably support the shaft (713) and the motor body (711), and a strain gauge unit (74) fixed to the fixed member (75) and configured to be biased by a contact of the motor body (711) when the motor body (711) rotates in a first direction with respect to the fixed member (75).