Wireless Fluid Cycle Counter Using Magnetic Flux Sensing
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Solution Overview
Problem
Current mechanical fluid transmission cycle counters in industries like landfill gas are prone to errors, corrosion, and require visual access, leading to increased costs and complexity, as well as labor-intensive and error-prone data collection processes.
Innovation Solution
An electronic fluid transmission cycle counter with a wireless interface, featuring a micro-controller, wireless transceiver, magnetic flux sensor, and diagnostic ports, which eliminates mechanical components, provides accurate and corrosion-resistant data collection, and allows remote data access through RF communication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical counters are used to record fluid transmission cycles, then the device can physically count cycles through mechanical means, but the device becomes prone to corrosion, produces erroneous counts, and requires visual access for reading
Solution Approach 1:
The patent replaces the mechanical counting system with an electronic sensor system. The electronic sensor detects fluid transmission cycles and sends signals to a microcontroller, eliminating mechanical components that are susceptible to corrosion and mechanical failure. This substitution directly resolves the contradiction by maintaining counting functionality while removing the harmful effects of corrosion and mechanical errors.
Solution Approach 2:
The patent introduces a magnetic flux source and magnetic flux sensor as intermediaries between the fluid transmission process and the counting mechanism. The magnetic flux source generates a magnetic field that is interrupted by the fluid flow, and the magnetic flux sensor detects these interruptions to trigger cycle counting. This intermediary system eliminates direct mechanical contact with corrosive fluids while maintaining accurate cycle detection.
2Ease of operation
If mechanical counters are installed close to the process for accurate reading, then visual access is improved, but the routing becomes more complex and installation cost increases
Solution Approach 1:
The patent replaces the visual reading mechanism with an electronic display and wireless communication system. The microcontroller processes sensor signals and displays cycle counts on an LCD screen, while a wireless transceiver enables remote data transmission. This eliminates the need for complex routing to provide visual access, as data can be viewed locally on the device or remotely via wireless communication.
Solution Approach 2:
The patent integrates multiple functions into a single device: the electronic sensor detects cycles, the microcontroller processes data, the LCD display shows readings, and the wireless transceiver enables remote communication. This multi-functional integration eliminates the need for separate reading devices and complex routing, allowing the device to serve multiple purposes at the installation location.
3Productivity
If technicians manually read mechanical counters in harsh environments, then data collection is performed, but labor time increases and human errors occur
Solution Approach 1:
The patent implements self-service functionality where the electronic sensor automatically detects fluid transmission cycles, the microcontroller processes the signals, and the system displays and transmits data without human intervention. The wireless transceiver automatically sends data to remote devices, eliminating the need for technicians to manually read counters and reducing labor time and human errors.
Solution Approach 2:
The patent incorporates feedback mechanisms where the electronic sensor continuously monitors fluid transmission and provides real-time data to the microcontroller, which updates the display and wireless transmission. This continuous feedback loop ensures accurate, up-to-date data collection without requiring manual intervention, improving productivity while minimizing time loss.
4Reliability
If mechanical counters are used in corrosive gas environments, then cycle counting is performed, but the device corrodes and fails over time
Solution Approach 1:
The patent replaces mechanical counting components with electronic sensors and a microcontroller that are enclosed in a protective housing. The electronic components are not subject to the same corrosion mechanisms as mechanical parts, and the housing provides additional protection against corrosive gases. This extends the device lifespan while maintaining reliable counting functionality in harsh environments.
Solution Approach 2:
The patent uses a magnetic flux detection system as an intermediary that requires no direct contact with the fluid or environment. The magnetic field penetrates the housing and detects cycles without the sensing components being exposed to corrosive gases, thereby protecting the device and extending its operational life in harsh environments.
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 electronic counter enhances accuracy, reduces labor and human errors, and simplifies data collection by enabling wireless communication, making it suitable for harsh environments and reducing installation complexity.
Implementation Method 1
a magnetic flux sensor, and diagnostic ports
Data Source
AI summary
An electronic sensor for counting of fluid transmission cycle with wireless interface is disclosed that reduces or eliminates problems with mechanical counters by an electronic fluid transmission cycle counter that is more accurate, reduces labor, improves time efficiency, and removes human error from reporting the fluid cycle count values. The electronic sensor with wireless interface to count the fluid transmission cycles eliminates the mechanical aspect of current counters the landfill gas industry uses.